WO2000078163A2 - Puffable half-product - Google Patents

Abstract

A system and method for distributing, preparing and consuming puffable half-products is disclosed. Puffable half-products can be expanded or puffed to produce cereals, cereal-based snacks and beverages through exposure to a suitable energy source. The half-products can be shipped through various channels of trade in bulk quantities or consumer-sized packages to an intermediary or directly to the end user. These dense pieces or pellets are not fragile and have a virtually unlimited shelf life. Furthermore, unlike conventional foods that have already been puffed long before reaching the consumer, these puffable food products can be puffed shortly before consumption. As a result, the consumer is now able, for the first time, to enjoy the full flavor and crispness of finished cereals, snacks and beverages while still 'freshly puffed' and, in certain variations, while still warm and aromatic from finish preparation. By providing consumers with access to these half-products and means to puff them, and a variety of toppings and additives, every serving of cereal, cereal-based snack and beverage can now be customized to suit a particular end user's tastes and/or dietary needs.

Description

FOOD DISTRIBUTION. PREPARATION AND CONSUMPTION

SYSTEM

This application claims the benefit under 35 U.S. C. 119 (e) of U.S. Provisional Application Serial No. 60/139,928 filed on June 18, 1999, hereby incorporated by reference in its entirety.

Field The present invention relates to methods of distributing, preparing and consuming food, and in particular to a distribution, preparation and consumption system for puffable half-products.

Background There is a growing market for specialty or gourmet foods and beverages that are freshly prepared and served. The coffee industry, for example, has experienced tremendous growth recently as consumers have developed a taste for specialty coffees. Consumers are not only purchasing specialty coffees in coffee houses and restaurants, but are also making specialty coffees at home with their own microwaves, coffee makers, cappuccino and espresso machines. The wide variety of coffees and creamers on the market today, together with the appropriate in-home appliances, allow consumers to create unique coffee drinks to suit their particular tastes. Additionally, the use of coffee grinders either in the store or at home also provides consumers with a fresher product as compared to coffees that have been pre-ground by the manufacturer. Despite the strong demand for freshly prepared foods and beverages, and in particular, for bagels and bakery goods, dry cereal and snack products, such as Wheaties® or Bugles®, are not known to be available as freshly puffed foods. Rather, such foods are purchased by consumers as "cold," ready-to-eat finished products. These products are consumed without further preparation, although in the case of cereals, products such as milk and fruit are often added to enhance or alter their taste and texture. Although there is little or no availability of freshly puffed dry cereals and snacks, there have been some limited efforts to develop "half-products" for microwave puffing. For example, U.S. Patent No. 5,102,679 to Whalen et al., describes half-products which are adapted to be puffed by using home-microwave heating to form puffed food products. The half-products in Whalen are made from high shear dough and use a topical sugar coating to reduce adhesion between the pellets that can occur during storage.

Moreover, the current and well-established paradigm of ready-to-eat cereal and snack manufacturing and distribution has had the effect of directing attention away from considering alternative or different approaches in this area. What is needed, therefore, is a system and method of distributing, preparing and consuming food products that can meet the varied needs of each individual consumer.

Summary A system and method for distributing, preparing and consuming puffable half-products is disclosed. Puffable half-products can be expanded or puffed to produce cereals, cereal-based snacks and beverages through exposure to a suitable energy source. The half-products can be shipped through various channels of trade in bulk quantities or consumer-sized packages to an intermediary or directly to the end user. These dense pieces or pellets are not fragile and have a virtually unlimited shelf life. Furthermore, unlike conventional foods that have already been puffed long before reaching the consumer, these puffable food products can be puffed shortly before consumption. As a result, the consumer is now able, for the first time, to enjoy the full flavor and crispness of finished cereals, snacks and beverages while still "freshly puffed" and, in certain variations, while still warm and aromatic from finish preparation. By providing consumers with access to these half-products and means to puff them, and a variety of toppings and additives, every serving of cereal, cereal-based snack and beverage can now be customized to suit a particular end user's tastes and/or dietary needs. By also serving these products with a hot or cold beverage, such as hot tea or any type of coffee drink, refrigerated milk and/or juice, a complete meal or snack can be provided.

In one embodiment, a consumer can select from any number of bulk containers having various finished or puffed food products that have been prepared offsite and shipped to the food service facility. In this embodiment, an assortment of toppings and additives is also available for added customization. Prior to making a selection, the consumer can further optionally complete a health and nutrition survey. The survey results can be used to provide one or more recommended choices to the consumer. The consumer can then select and package the desired choices. The survey, recommendation, selection and packaging steps can be completed manually, with any type of automated means, or by any combination of manual and automated means. Additionally or alternatively, an in-house expert can be used who reads and interprets the survey results, thus personally providing food recommendations to the consumer based on the survey results.

The half-product pellets can also be packaged and puffed in a variety of ways, thus providing the consumer with many choices on the type of product to purchase and the type of preparation method to use. Such packaging can include instructions on how to prepare the pellets. In one embodiment, a "moisturizing agent," such as oil, is admixed with the pellets subsequent to the puffing step, so that added coatings, toppings and additives can better adhere to the surface of the final product. The package can also include savory toppings, and instructions on how to apply the toppings. The ability to package the half-product pellets of the present invention in so many varied ways creates unlimited choices for the consumer to customize a particular serving to suit individual tastes and dietary requirements. The added convenience in one embodiment of having the package form a bowl allows the consumer to easily take along individual servings of a favorite cereal while traveling away from home.

Half-product pellets can be distributed in bulk or in packages to the consumer using various distribution systems. One system of distribution involves distributing half-product pellets to the retail market in consumer-sized packages. This system of distribution typically involves the consumer taking-out a quantity of half-product pellets, and preparing and consuming the end product at home, work or other location. In an alternative embodiment, the consumer can have packages delivered directly to his/her home by using any of a number of convenient options, such as an exclusive delivery service, an Internet-based mail order company, and so forth. In another alternative embodiment, pellets can first be shipped in bulk from the manufacturing facility to a puffing facility located close to retail markets, remote from the manufacturing facility, where the pellets prepared are for consumption according to local tastes. This type of distribution system provides a unique and efficient way to distribute needed foodstuffs to consumers in a manner well adapted to third world countries, where shipping perishable ready-to-eat products long distances is problematic. As a result, these consumers can enjoy a fresher and more desirable end product.

The half-product pellets can be puffed in a variety of commercial and consumer devices that are designed to provide a suitable source of energy to cause rapid expansion of particulates through release of bound moisture. In one embodiment, the apparatus has the capability of meeting the different time- temperature puffing profiles of the various types of half-product pellets. In a particular embodiment, the preparation or puffing method is designed to rapidly warm and thereby puff puffable half-product pellets having both a suitable moisture content and an unpuffed density, such as about five (5) to 15% and 0.7 to 1.5 g/cc, respectively. In another embodiment, the puffing apparatus is adaptable for use as either a consumer or a commercial device.

In yet another embodiment, the apparatus includes a computer control system having instructions for storing, displaying and processing recipe information necessary to operate the apparatus such that the entire puffing process is completed automatically. One example of such an apparatus is a small-scale computer- controlled dryer/toaster/enrober that quickly puffs, toasts and coats the half-product pellets to produce freshly puffed food products, such as cereals or snacks. In an alternative embodiment, this apparatus can further include a size-reducer, such as a grinder to finely grind the half-product pellets for use in a beverage, frozen cereal- based snack, hot porridge-type cereal, or as a topping.

These and other features, aspects and advantages of the present invention will become better understood with regard to the following description, appended claims and accompanying drawings.

Brief Description of the Drawings Fig. 1 is a simplified schematic diagram of a system of food distribution, preparation and consumption in a food service facility having bulk containers in accordance with one embodiment of the present invention.

Fig. 2 is a simplified schematic diagram of an alternative system of food distribution in a food service facility having bulk containers, with food preparation and consumption either at the facility or at another location in accordance with one embodiment of the present invention. Figs. 3 A and 3B are simplified schematic diagrams of a system of bulk food distribution from a food service facility, with food preparation and consumption at another location in accordance with one embodiment of the present invention.

Fig. 4 A is a simplified partial cut-away perspective view of a consumer- sized container in accordance with one embodiment of the present invention. Fig. 4B is a simplified perspective view of a folded microwave package surrounded by outerwrap in accordance with one embodiment of the present invention.

Fig. 4C is a simplified perspective view of an unfolded microwave package having microwave puffing instructions in accordance with one embodiment of the present invention.

Fig. 4D is a detailed view of the microwave puffing instructions on the unfolded microwave package in Fig. 4C in accordance with one embodiment of the present invention.

Fig. 5 A is a simplified schematic diagram of a half-product pellet preparation method wherein the pellet package is a microwavable box with instructions which forms a bowl in accordance with one embodiment of the present invention.

Fig. 5B is a detailed view of the instructions on the microwavable box in Fig. 5 A in accordance with one embodiment of the present invention.

Fig. 6 is a plan view of the microwavable box, which forms a bowl in accordance with one embodiment of the present invention.

Figs. 7A and 7C are cross sectional views of an expandable bowl having half-product pellets contained within shown before and after the bowl has been expanded, respectively.

Figs. 7B and 7D are top views of the expandable bowl having half-product pellets contained within shown before and after the bowl has been expanded, respectively, in accordance with one embodiment of the present invention.

Fig. 7E is a cross sectional view of an expandable bowl having a freshly puffed food product contained within in accordance with one embodiment of the present invention.

Fig. 7F is a top view of an expandable bowl having a freshly puffed food product contained within in accordance with one embodiment of the present invention. Fig. 8 A is a simplified partial cut-away perspective view of a cereal box- sized package having half-product pellets contained within and puffing instructions on the outside.

Fig. 8B is a detailed view of the puffing instructions on the cereal box-sized package in Fig. 8 A in accordance with one embodiment of the present invention. Fig. 9A is a simplified partial cut-away perspective view of a multi-serving sized package having toppings instructions in accordance with one embodiment of the present invention.

Fig. 9B is a detailed view of the toppings instructions for spray and powdered toppings on the multi-serving sized package in Fig. 9A in accordance with one embodiment of the present invention.

Fig. 9C is a simplified partial cut-away perspective view of an alternative multi-serving sized package having squeeze and sprinkle toppings instructions in accordance with one embodiment of the present invention. Fig. 9D is a detailed view of the squeeze and sprinkle toppings instructions on the alternative multi-serving sized package in Fig. 9C in accordance with one embodiment of the present invention.

Fig. 10A is a simplified schematic diagram of a food distribution system from a manufacturing facility to a retail outlet in accordance with one embodiment of the present invention.

Fig. 1 OB is a simplified side view of a pellet carton containing multi-serving packages in accordance with one embodiment of the present invention.

Fig. 11 A is a simplified schematic diagram of a shop-at-home food distribution system from a manufacturing facility to a distributor in accordance with one embodiment of the present invention.

Fig. 1 IB is a simplified schematic diagram of an alternative shop-at-home food distribution system from a manufacturing facility to a distributor in accordance with one embodiment of the present invention.

Fig. 12 is a simplified schematic diagram of a food distribution system from a manufacturing facility to a puffing facility in accordance with one embodiment of the present invention.

Fig. 13 is a simplified schematic diagram of a continuous commercial method for puffing half-product pellets in accordance with one embodiment of the present invention. Fig. 14 is a simplified schematic diagram of batch commercial methods for puffing half-product pellets in accordance with one embodiment of the present invention.

Fig. 15A is a simplified partial cut-away perspective view of a commercial vending machine in accordance with one embodiment of the present invention. Fig. 15B is a simplified schematic diagram of a batch method for puffing half-product pellets in accordance with one embodiment of the present invention.

Fig. 16 is a simplified schematic drawing of a method of puffing half- product pellets at home using an air popper in accordance with one embodiment of the present invention.

Fig. 17 is a simplified schematic drawing of an alternative method of puffing half-product pellets at home using a "tumbler" in accordance with one embodiment of the present invention.

Fig. 18 is a simplified schematic diagram of another alternative method of puffing half-product pellets at home using a pellet puffer in accordance with one embodiment of the present invention.

Detailed Description of Invention In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized. It is also to be understood that structural, procedural and system changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.

A system and method for distributing, preparing and consuming farinaceous puffable half-products is disclosed. The half-products can be distributed in bulk quantities or in consumer-sized packages to an intermediary or directly to the end user. These dense pieces are not fragile and have a virtually unlimited shelf life. Furthermore, unlike conventional foods that have already been puffed long before reaching the consumer, the puffable food products in the present invention can be puffed shortly before consumption. As a result, the consumer is now able, for the first time, to enjoy the full flavor and crispness of finished cereals, snacks and beverages while still "freshly puffed" and, in certain variations, while still warm and aromatic from finish preparation.

Various terms used throughout the description are defined first, followed by a brief overview of half-product manufacturing. Food preparation and consumption associated with a food service facility is described next, followed by details on puffable half-product pellets, including food preparation "kits" having instructions for preparation and consumption. Various types of packaging for the kits are also described, including packages that form serving bowls. Details on the various distribution systems are covered next, including distribution of puffable half-product pellets to the retail market in consumer-sized packages and distribution of bulk quantities of pellets to puffing facilities remote from the manufacturing plant, where the food product is prepared according to local tastes. Details regarding types of commercial and consumer or in-home apparatus for preparing the puffable half- product pellets are covered next, followed by a brief conclusion highlighting some of the advantages of the various embodiments of the invention.

INTRODUCTORY DEFINITIONS As used herein, the term "half-product pellets" means grain-based products that are generally fabricated from farinaceous cooked or partially-cooked cereal doughs. These half-product pellets may take the form, for example, of cereal pellets or snack pellets, such as pasta pellets. Cereal pellets are generally smaller in size as compared with snack pellets. The term "pellet," when used without qualification, refers to a puffable piece of a gelatinized dough product (i.e., a half-product) that is at least partially gelatinized, and which is roughly rounded in shape. The term "pellet" is intended to broadly encompass "flavor- integrated" pellets, which are pellets having flavorings and seasonings added into the dough, "flavor-coated" pellets, which are pellets having flavorings and seasonings added as a coating, or "regular" pellets, which are pellets having no additional flavorings added. Flavor- integrated pellets and flavor-coated pellets are both considered to be "pre-flavored" pellets. The term "half-product" as used herein includes the term "half-product pellets" which can consist of one or more pellets, as well as other half-products which include one or more elongated "pieces" with fillings and one or more puffable pieces of any type of simple or complex shape. This includes regular geometric shapes (e.g., squares, rounds, triangles, hexagonals, tubes, and so forth) and irregular shapes, which can be patterned (e.g., figurines, animals, trees, holiday shapes, stars, pillows, twists, wagon wheels, etc.) or unpatterned. Many of the geometric shapes, such as hexagonal, and various combinations of regular and iπegular shapes (e.g., crab, palm tree and bird), can be interlocked together or "tessellated" such that when cut, there is no web or waste left over. Further, such shapes may be relatively large in size. Larger half-products produce larger snacks known as hand-to-mouth (HTM) snacks (e.g. "Bugles®"). In some cases, the "half- product" is about the size of a French fry, pretzel, breadstick or larger and can include, for example, a low calorie bar snack. A half-product also includes one or more "sheets" of cooked cereal dough of various sizes and shapes, including, but not limited to, squares, rectangles, triangles, rounds, and other geometric shapes from less than about 25 cm up to about one (1) m or more. Further, any number of sheets can be combined to make a two-dimensional or a three-dimensional shaped half-product. The sheets can also have any type of surface pattern or design as described above, including any type of repeating or alternating pattern or design. This pattern can be on one or both sides of a particular sheet, or on one or more sheets of a particular shape. Unless otherwise stated, the plural terms "pellets," "half-products," and "half-product pellets" are also intended to encompass one singular pellet, half-product and half-product pellet, and vice versa. In the following description it is to be understood that puffable half-products of various shapes and sizes can be used even though the term "pellets" is used. A half-product can also be "pre-sweetened" by any suitable means, such as with a suitable amount of sugar, honey, and so forth.

The term "puffable" refers to an expandable half-product having a moisture content of about five (5) to 15% that expands upon heating to a size of at least about two (2) to about ten (10), possibly up to about 15 times larger than its original dimensions. In one embodiment, the half-product puffs to about three (3) to ten (10) times larger. The term "puffed" is used herein to collectively refer to a variety of finished forms, including, but not limited to, puffs, flakes, shreds, granola pieces, finely ground particles and so forth. "Puffed pieces" are generally characterized by a density that has been reduced from an unpuffed density (typically ranging from about 0.7 to 1.5 g/cc) to a finished or puffed absolute density which is lower, ranging from about 0.06 to 0.7 g/cc, depending on the type of half-product used. The term "additive" is intended to encompass any type of food ingredient added to the food product (puffed or unpuffed) at any time during the manufacturing, distributing and preparing steps. A "topping" is one type of additive which typically stays on "top" of the puffed food product, although a "topping" can also be applied as a "coating" such that it adheres to some or all of the puffed food pieces, with or without the assistance of a carrier substance. Liquids in any form are also considered to be additives. Please note that embodiments discussing the use of "toppings" can also include the use of any type of "additive."

The terms "final product," "end product" or "puffed food product" are considered to include a variety of forms, even if only a few specific forms, such as a RTE cereal or snack, are listed with respect to a particular embodiment.

Specifically, the term "final product" is considered to include any and all of the final products described herein and their equivalents, including, but not limited to, final products which contain the puffed food product in either a whole or a size-reduced form, i.e., partially ground, finely ground, and so forth. This includes a final product in which the puffed food product is served hot, warm, frozen, chilled or at room temperature. A final product further includes use of the puffed food product as a topping, as an additional ingredient that is either admixed or blended into another food, such as a liquid or semi-liquid, which can be frozen, chilled, warm, hot or at room temperature. In addition to cereals and snacks, examples of "final products" include any type of hot and cold beverages, yogurts, gelatins, and hot cereals containing finely ground puffed pieces, as well as cereal-based snacks of varying sizes. This also includes frozen cereal-based snacks such as ice creams, yogurts, sherbets, Popsicles, fudgsicles and chilled beverages such as smoothies, and so forth. This further includes final products in which any type of additive has been applied as a coating, topping, glazing, an additional ingredient, and so forth. The final product can also be a "sheet"-type product made from a "sheef'-shaped half-product, and can include pastries, waffles, pancakes, and so forth, including any type of three-dimensionally shaped puffed food product. The final product can also be any type of "pressed" product such as a granola bar. A ready-to-eat (RTE)

"cereal" is typically defined as having about 35-60 half-product pellets or more in about ten (10) g of puffed food product. Similarly, a "snack" product is typically defined as having about one (1) to 20 half-product pellets or more, up to about 30 half-product pellets in about ten (10) g of puffed food product, and includes a single half-product pellet weighing up to about seven (7) grams or more.

"Puffing" or "expanding" refers to a drying process in which the half- product is dried rapidly enough to cause the half-product to expand or puff. Puffing occurs when bound moisture in a liquid state is converted to a vapor phase and "suddenly" released during exposure to a suitable energy source, such as thermal or microwave energy. If the half-product is dried too slowly, it remains hard, rather than softening and puffing. This is in contrast to "popping" or "exploding" which occurs when popcorn is popped. This is also in contrast to "cooking," which is defined herein as the first heat or mechanical treatment that a mixture receives which essentially forms it into a dough. It is this dough, i.e., a processed grain- based unexpanded food product, which is then fabricated into the various half- products described above. (Some of these fabrication processes, such as the forming and flaking mill, as well as other processes further downstream, such as gun puffing, and so forth, can cause the starch in the dough to become gelatinized. As a result, many in the industry refer to the pre- formed dough as only "partially" cooked). It should be noted that the process of "puffing" as described herein, does not cause the starch to become gelatinized. "Puffing" is further distinguished from "reheating" of a finished puffed RTE cereal or snack piece that has a lower moisture content and density, such as about one (1) to about five (5)% moisture and about 0.02 to about 0.7g/cc, respectively. Such reheating of a finished product would likely be unsuccessful in that it may burn, scorch and/or char the pieces, not generate the fresh flavor, toughen the texture rather than soften the piece, and so forth. "Puffing" is also distinguishable from the gradual expansion of a food product due to an uptake of liquid in the absence of applied energy, which is not a "cooking" process, per se. This includes, but is not limited to, the "soaking" up of a liquid, such as milk, by a conventional cereal product, and so forth. It is important to note, however, that the food products of the present invention can be puffed in the presence of a liquid, such as oil, if desired.

OVERVIEW OF PELLET MANUFACTURING As noted above, pellets are formed from farinaceous doughs that expand or puff when subjected to a suitable energy source. Such doughs are puffed by causing trapped moisture to expand from the liquid state to the vapor phase. Rapid hea.;ng and rapid depressurization are the methods commonly used to convert pellets into puffed, crisp food pieces. Rapid heating and depressurization can take place in less than a second up to a few seconds or more. This process can also cause flavors to be generated and released, producing a pleasant aroma, particularly in whole grain variations.

One well-known method of rapid depressurization of a superheated cereal dough is known as "gun puffing." With this method, the pellets are heated under pressure to about 200 °C. The sudden release of the pellets to atmospheric pressure causes the moisture within the pellets to be instantly converted to steam, thus causing expansion of the pellets. Microwave heating has also been taught generally as being useful as a rapid heating/puffing method for various starch-containing materials. See, for example, Whalen, supra, and U.S. Patent No. 5,695,805 to Borek, et al., both of which are hereby incoφorated by reference.

Many consumers also enjoy the flavor of toasted cereals. Generally, such known toasting techniques involve intense heating including radiant and/or conduction heating which involve heat transfer from the exterior of the piece inward. The operation of the gun puffing apparatus can also be adjusted to provide some degree of toasting to the resulting puffed cereal pieces, although pellet throughput is necessarily decreased. For alternative methods of toasting, see U.S. Patent No. 5,200,222 to Schwab, et al., which is hereby incorporated by reference. In general, pellets may be manufactured from any suitable type of dough, such as no shear, low shear, lightly worked, or high shear doughs. Low shear doughs are doughs that are not highly worked. Lightly worked doughs are doughs which are worked more than low shear doughs, but not as much as high shear doughs. Similarly, high shear doughs are doughs that are highly worked. All of the various types of doughs have shear levels known in the art. No shear doughs are typically made in a batch cooker. Low shear doughs can be produced using a "James Puffer" or "James" machine. The basic design of the James Cooker is described in U.S. Patent Nos. 2,233,919; 2,263,301 and 2,272,007 to T.R. James, each of which is hereby incorporated by reference. Specifically, the batch cooker and the James Cooker receive whole cereal grains, flour or more coarsely sized grain pieces. These ingredients can be from any suitable type of grain or a combination of grains, such as wheat flour, which has been admixed with a suitable amount of water and salt. The mixture cooks for a suitable amount of time, which can be about one (1) hour or more to provide a cooked cereal mass or dough. For the batch cooker, the resulting cooked dough has a moisture content of about 25-40%. For the James cooker, the cooked cereal dough can have a moisture content of about 10-30%. In another embodiment, the cooked cereal dough from the James cooker has a moisture content of about 20-28%. The resulting cereal mass either from the batch cooker or the James cooker is then worked to form a cooked cereal dough. For both cookers, the cooked cereal dough can then be shaped into half-products. The half-products can be dried to have moisture contents that are shelf-stable, but nonetheless puffable, ranging from about seven (7) to about 14%. The pellets can be formed into their desired final shape, e.g., rings, spheres, squares, rounds, triangles, hexagonals, tubes, etc., or further processed into other desired shapes. For example, spherical pellets can be pressed into flakes. The shaped pellets can then be puffed, such as by rapid heating, to form warm puffed products. The puffed pieces can also be toasted. Toasting can be done as part of the puffing process, as a separate subsequent step or partially during both the puffing process and a subsequent toasting step. Finished puffed cereal products prepared from "no shear" or "low shear" doughs exhibit desirable visual and organoleptic attributes that are especially desirable for adult oriented Ready-to-Eat (RTE) cereal products, such as flakes (e.g., Wheaties®, a whole grain wheat flake cereal), rings (e.g., Cheerios®, a whole grain oat-based puffed cereal), and so forth. Such organoleptic attributes include low tooth compaction upon consumption, better overall eating properties than high shear doughs of the same formulation, and so forth. Low shear doughs are also considered to have a better "appearance" than other types of doughs. Specifically, because of the heterogeneous nature of these doughs, there are more "variations" within a single piece, helping to give low shear doughs a less processed, more natural appearance. These and other benefits of low shear doughs are described in U.S. Patent Application Serial Number 09/025,976 to Robie, entitled, "RTE Cereal and Method of Preparation" and U.S. Patent Application Serial Number 08/946,262 to Hurd, entitled, "Twin Screw Pre-Conditioner Unit and Method," both of which are hereby incoφorated by reference. Low shear doughs are also discussed in PCT International Publication No. WO 991/7622 to Hurd, which is hereby incoφorated by reference.

As noted above, finished puffed cereal products can also be prepared from "high shear" doughs. High shear doughs are highly-worked homogenous doughs that can be prepared by any number of known methods, including, but not limited to, twin screw extruders. See, for example, Whalen, supra. High shear doughs have about the same moisture content as no shear and low shear doughs made in a James cooker, namely about ten (10) to 30%. Although high shear doughs typically exhibit better puffing properties than low shear doughs of the same formulations, the resulting products can be visually undesirable and generally have fewer organoleptic attributes. Lightly-worked doughs are described in U.S. Patent No. 5,165,950 to Boehmer, which is hereby incoφorated by reference.

Since the required energy input to puff a half-product properly is a function of many factors, including shape, size and content, it follows that the energy requirements can be varied depending on the particular type of half-product being puffed. In some cases, only a slight variation in heating type or time can cause significant changes in the final product. For example, the final product can be made to be "chewy" rather than "crispy" simply by adjusting the half-product type and puffing methods. As noted above, the half-product pellets expand rapidly or suddenly, but non- violently, when subjected to energy, rather than exploding or bursting, as with popcorn. This is due to the type of starch present in the pellets. Specifically, the starch in the half-product pellets is processed or "cooked" starch which tends to be randomly oriented, not appreciably ordered, and contains few granules. It should be noted that the process of cooking initially causes raw or native starch, which is comprised of granules (i.e., many starch molecules tangled together), to lose its ordered structure and become amoφhous. As cooking continues, the granules swell in the presence of water, and essentially fall apart, such that the starch molecules untangle. Further, the moisture present in the half-products is bound throughout the matrix.

"Native" or unprocessed starch is the type of starch present in popcorn. Popcorn further contains a hard outer shell (i.e., hull or pericap) that surrounds the starch and also contains endogenous moisture, moisture that is within the actual plant cells. When a popcorn kernel is heated, the starch inside the shell softens, the liquid inside the cells is converted to steam, which builds up pressure within the shell. When the exploding pressure is reached, the shell ruptures catastrophically. The two portions or halves of the shell then fold back from either direction, causing the molten mass, i.e., the starch, inside to "fan" out or erupt into the atmosphere, as the endogenous moisture is released. However, it is known that popcorn can expand even if a portion of the shell is absent, such as with a partial kernel. This is because popcorn's starch, which is ungelatinized, is unique in that it expands explosively inside out, rather than swelling or puffing in all directions, as with the half-product pellets. In contrast, when the half-product pellet, which contains no hull or pericap, is exposed to a suitable energy source, the entire half-product softens, causing the water in the half-product to become a vapor. As the vapor is formed, it takes up more space, causing expansion. Then, as the vapor begins to leave the soft expanded half-product, the half-product dries out and becomes firmer. Upon cooling, the final structure "sets," due to some of the expansion now being locked in place, resulting in a puffed food product.

The change in the size of a half-product pellet due to expansion can vary from about two times (2x) its original size to about five times (5x), up to about ten times (lOx), possibly up to about 15 times (15x). (This is in contrast to popcorn kernels, which typically expand 20 to 40 times their original size when popped). The variation in expansion of the half-product pellets is due to any number of factors including, but not limited to, the dough composition of the half-product, processing of the dough during puffing, half-product moisture content, half-product shape, half-product size and puffing conditions. As noted above, the primary ingredient present in cooked cereal dough is a cooked cereal grain material. The cooked cereal material can be made from any cereal grains and starch containing vegetables including, but not limited to wheat, oats, rice, corn, potatoes, barley, rye, sorghum, triticale, amaranth, and mixtures of these. The cooked cereal mass can also optionally include conventional cereal ingredients such as salt, minerals, malt syrup, sugar(s), added fiber (e.g., bran, cellulose, pectin, psyllium, inulin, beta glucans, and mixtures thereof), vitamins, flavorings, colorants, and so forth. In one embodiment, the cereal grain material comprises at least a portion of a whole grain ingredient, e.g., soft wheat or whole oats. In other embodiments, various cereal materials such as cereal flours (whether whole grain or a cereal flour fraction) or cut cereal pieces can be used. Half- products can also contain certain ingredients to help control puffing, such as fatty triglycerides and emulsifiers.

Note that the manner in which half-products are made is not critical to the invention, except in such cases where half-products are specially manufactured according to one or more embodiments.

EMBODIMENTS RELATING TO FOOD SERVICE FACILITIES According to one example embodiment, bulk quantities of half-product pellets can be shipped to a food service facility for preparation and consumption on site or off-site. The food service facility can be any type of facility that prepares, sells or serves food to consumers. In one embodiment, the food service facility is a gourmet food store that primarily sells a variety of half-product pellets, cereals, snacks and associated products. In an alternative embodiment, the food service facility is any type of mass outlet such as a franchised fast- food restaurant. In another alternative embodiment, the food service facility can be any type of facility where a person can purchase and/or consume food. This includes, but is not limited to, a grocery store, restaurant, bakery, bagel shop, cafeteria, kiosk, bar, deli, entertainment facility (e.g., movie theater, bowling alley, etc.), multi-puφose facility such as an aiφort, hospital-type facility, railroad station, bus station, coin laundry facility, department store, and so forth.

Restaurant-type food service facilities can offer puffable half-products to the consumer in a variety of ways. For example, the food service facility can have menus offering several choices of half-products and toppings. Alternatively, the food service facility can offer a self-service buffet line. The buffet line can include a puffing station where the consumer watches as his/her made-to-order serving is prepared. Alternatively, or in addition, the buffet line can include single servings of freshly puffed food products and toppings for the consumer to choose from. In one embodiment, each of the various types of food service facilities offers products produced from differing recipes, depending on their particular pricing scheme.

To further describe this embodiment, reference is now briefly made to Fig. 1 , which provides a schematic diagram of one embodiment in which half-product pellets are prepared and consumed in a food service facility. Although Fig. 1 is described primarily in terms of freshly puffed "cereals," this embodiment also encompasses any of the puffed food products described herein, including, but not limited to, freshly puffed snack foods (such as frozen and non- frozen cereal-based snacks which can be made from puffed products which have been ground), ground hot cereals, beverages, and so forth. As shown in Fig. 1, one or more bulk containers 120 are provided in a food service facility 122. Each bulk container 120 holds a given volume or weight of half-product pellets and each bulk container 120 can contain a different type of half-product pellet 124a, 124b and 124c (hereinafter all referred to as "124") as shown. In one embodiment, each bulk container 120 holds about four (4) L (about one (1) gal) to about 20 L (about 5.3 gal) of any one type of half-product pellet 124 having a particular content, shape and size. Each bulk container 120 can be replenished with half-product pellets 124 as needed, depending on sales for that particular time period.

In response to a selection made by a consumer, food service facility personnel can gather a single serving 126 of half-product pellets 124 from one or more of the bulk containers 120 using a suitable gathering tool, such as a scoop 128. Alternatively, the consumer may gather the serving. The single serving 126 can be placed into any suitable type of serving container, such as a bowl 130. The single serving 126 can be any suitable size, and can be metered or measured by weight or volume. In one embodiment, the single serving ranges from a child-sized portion of about 25 grams (g) (less than about one (1) oz) to a hefty adult portion of about 100 g (less than about 3.6 oz), with an average-sized single serving weighing about 50 g (less than about 1.8 oz) or otherwise between about 30 to 60 g (between about one (l) to two (2) oz).

The single serving 126 is then puffed by any appropriate method using any suitable type of apparatus that can cause "puffing" or "expansion" of the half- product pellets 124. In one embodiment, a convection air oven is used. In another embodiment, any suitable type of microwave oven, hot air popper, frying chamber or vacuum is used. In a particular embodiment, any suitable low power device including, but not limited to, a microwave oven, having a power of less than about five (5) to about 50 kilowatts (kW) is used. In the embodiment shown in Fig. 1, the single serving 126 is subjected to convective heat for a suitable length of time in an adequately-sized convection air oven 132 to produce a single serving 126 of freshly puffed cereal (or cereal-based snack) 134 as an end product. The convection air oven 132 can be an air impingement oven or a common convection air oven. In one embodiment, the convection air oven 132 is an air impingement oven, which can deliver high velocity heated air through jets or orifices directed at and peφendicular to the upper and lower surfaces of the half-product pellets 124. In another embodiment, a Lincoln® Jet Sweep® oven or a Lincoln Impinger® Oven or a Lincoln AIM® oven, made in Lincoln, Nebraska, is used. The freshly puffed cereal 134 can then be removed from the convection air oven 132 and served to the consumer. In one embodiment, the half-product pellets 124 are admixed with topically-applied oil after puffing. In another embodiment, the half-product pellets 124 are admixed with topically- applied oil prior to puffing. Alternatively, or in addition, additives, such as toppings 136, especially those in powder form, and milk (or cream) 138 can be applied to the freshly puffed cereal 134 prior to serving it to the consumer as described below. In another embodiment, the toppings 136 are applied while the serving is still hot. In one embodiment, a selection of savory toppings 136 is provided, including, but not limited to, sugar, fruit, nuts, cheese, and so forth. In another embodiment, topically-applied oil is added together with one or more toppings 136 after puffing. In this embodiment, the oil, toppings 136 and freshly puffed cereal 134 are shaken or mixed together in a closed container, such as a bag, for about five (5) to about 20 seconds or more, until the freshly puffed cereal 134 is adequately coated with the selected toppings 136. With toppings or not, the consumer can consume a portion or all of the serving while it is still warm. In the embodiment shown in Fig. 1, the toppings 136 are added to the freshly puffed cereal 134 in any suitable manner to produce flavored freshly puffed cereal 140. This can be followed by the addition of milk 138, resulting in a single serving 126 of moist flavored freshly puffed cereal 142. Alternatively, the freshly puffed cereal 140 can be served without milk or cream 138.

Any of the end products described (134, 140 or 142) can be served to the consumer as a freshly puffed and steaming hot food product. In an alternative embodiment, the end products (134, 140 and 142) are served before the serving cools to ambient temperature, i.e., while the freshly puffed cereal 134 is still warm. In another alternative embodiment, the end products (134, 140 and 142) are served after cooling, but while still "freshly" puffed, i.e., while still having a "full, fresh" flavor or strong taste, as discussed further in Fig. 2. In yet another alternative embodiment, the end products (134, 140 and 142) are served within an hour of being puffed. In yet another alternative embodiment, the end products (134, 140 and 142) are served within two (2) to three (3) days of being puffed.

In one embodiment, the steps of gathering, puffing, applying additives and serving the consumer takes a minimum amount of time. In one embodiment, the entire process from gathering to serving takes less than about ten (10) minutes. In an alternative embodiment, the process takes less than about five (5) minutes. In one embodiment, the "puffing" step takes about 0.25 minutes. In the time line 144 shown in Fig. 1, the entire process takes about four (4) minutes, with the "gathering" step 146 taking about 0.5 minutes, the "puffing" step 148 taking about 0.3 to about two (2) minutes, the "applying toppings and milk" step 150 taking about one (1) minute, and the "serving" step 152 taking about 0.5 minutes.

The process as described can also include other steps not shown in Fig. 1 that may alter, enhance or simplify the distribution, preparation or consumption of the end product. For example, the gathering step 146 may be followed by a weighing step. Furthermore, certain steps, such as an additional weighing step, may have sub-steps that have not been discussed or shown in Fig 1. The steps as described can also be varied in any suitable manner to accommodate the particular type of equipment available, the type of facility being operated and/or the type of consumer being served. For example, instead of using a barrel for the bulk container 120, as shown in Fig. 1, the bulk container 120 can be any type of suitable container or a dispenser having a spout or outlet on or near the bottom, similar to the dispensers used for dispensing coffee beans. Such dispensers are particularly useful for self-serve operations. The dispenser can be designed to dispense just one single serving per use or can be designed to dispense half-product pellets for as long as the food service facility personnel or consumer keeps the dispenser open.

Even without special dispensing equipment, food service facility personnel or the consumer can choose to gather more or less than a single serving 126 and thereafter cause it to be puffed in the convection air oven 132. In one embodiment, the consumer puffs the desired quantity, such as a single serving 126 in a suitably located puffing device intended for use by consumers. In another embodiment, the puffing device is located in the area of the half-product pellets 124 and toppings 136 so the consumer can select and prepare their single serving in one convenient area. Additionally, although food service personnel may gather and puff the half-product pellets 124, the consumer, rather than the food service facility personnel, can add the desired toppings 136 and/or milk 138.

Fig. 2 shows an alternative embodiment of the present invention wherein food service facility personnel puff a bulk quantity 210 of half-product pellets 124a, 124b and 124c (hereinafter "124") in a puffing device, such as the convection air oven 132. The half-product pellets 124 can be contained within puffing containers 212 that are placed inside the convection air oven 132. In an alternative embodiment, a suitable amount of half-product pellets 124 can be poured into a puffing device that is designed to spew out the freshly puffed cereal 134 during puffing. (Again, although Fig. 2 is described primarily in terms of freshly puffed "cereals," the description that follows also encompasses all of the freshly puffed food described herein, including "snack foods," and so forth).

In one embodiment, the puffing facility 122 displays the resulting bulk quantity 210 of freshly puffed cereal 134 in a display area 214. In this embodiment, the food service facility 122 can receive bulk amounts of half-product pellets 124 in any desired packaging, such as a sack or barrel. In the embodiment shown in Fig. 2, the half-product pellets 124 arrive packaged in 25 kg (about 55 lb) sacks 216. A portion of the contents of the sacks 216 (e.g., one (1) to two (2) kg) is then transferred to one or more puffing containers 212 which are of any suitable size and shape. In one embodiment, each puffing container 212 is large enough to hold not only a bulk quantity 210 of half-product pellets 124, but to also hold the bulk quantity 210 of freshly puffed cereal 134 which is produced as a result of half- product pellet expansion.

In one embodiment, each puffing container 212 can hold about 15 L (about four (4) gal) to about 20 L (about 5.3 gal) or more of freshly puffed cereal 134. In another embodiment, each puffing container holds less than about 15 L (about four (4) gal). In the embodiment shown in Fig. 2, each puffing container 212 holds about five (5) L (about 1.3 gal) of freshly puffed cereal 134. In one embodiment, about one (1) L (about 3.8 gal) of a particular half-product pellet type weighs about 0.6 kg (about 1.3 lbs), and is known to expand to about three times (3x) its original size under certain puffing conditions. In this embodiment, if the five (5) L (1.3 gal) container 212 is filled with only about 1.5 L (about 0.4 gal) or about 1.8 kg (about four (4) lbs) of this type of half-product pellet, the entire bulk quantity 210 of freshly puffed cereal 134 can be contained within the container 212 after the puffing process is completed. In another embodiment, the half-product pellet weighs about 0.1 to 0.5 g.

The puffing container 212 can be made from any type of material that can withstand heat from the puffing process, such as glass, metal, or ceramic. In one embodiment, the puffing container 212 is insulated and one or more puffing containers 212 are used to display the freshly puffed cereal 134 in the display area 214.

Any number of puffing containers 212 can be used in the display area 214. In the embodiment shown in Fig. 2, the display area 214 has three (3) puffing containers 212, each containing a bulk quantity 210 of RTE freshly puffed cereal 134. The display area 214 can also have a selection of toppings 136 and milk 138. In one embodiment, the display area uses a suitable heating or warming device (not shown in Fig. 2) to keep the freshly puffed cereals 134 warm. The display area 214 can be arranged as a self-service or full-service area. In one embodiment, personnel of the food service facility 122 use a gathering tool, such as a scoop 128, to gather a single serving 126 of freshly puffed cereal 134 from the display area 214 in response to a selection made by the consumer.

In one embodiment, the freshly puffed cereal 134 is served to the consumer while it is still hot. In an alternative embodiment, the freshly puffed cereal 134 is served to the consumer while it is still warm from being expanded, i.e., before it reaches ambient temperature. In another alternative embodiment, the food service facility 122 uses a bakery- style operation to prepare and serve the freshly puffed cereal 134 on a daily basis. Specifically, the freshly puffed cereal 134 is prepared in bulk each day as described above, and is served to the consumer even after it has cooled, but while still "freshly" puffed. Freshly puffed cereal 134 can start to lose its full, fresh flavor when flavor volatiles, which are dissolved in the freshly puffed cereal 134, e.g., alcohols, amines, aldehydes, etc., begin to vaporize. (Volatiles are known to be readily vaporizable at relatively low temperatures, due to vapor pressure levels). Volatiles begin to escape rapidly immediately after puffing, causing a continuous change in flavor levels over a relatively short period of time, such that a food product eaten minutes after puffing, although still considered "fresh" or at "peak flavor" has a different flavor level than a food product eaten earlier, such as immediately after puffing. As the volatiles escape, not only is the amount of each particular volatile being reduced or diminished, the overall profile of the volatile content is also changing, which can also affect the flavor of a food product. Over time, the rate of escape of these volatiles decreases, reaching a nearly steady-state condition, in which relatively few volatiles are escaping. Once the escape of volatiles into the surrounding air has reached this nearly steady state condition, i.e., once the volatile level has been substantially diminished, a food product can be considered to have lost its "fresh" flavor. Although this near-equilibrium condition can last for months, it is believed that, over time, so-called "good" flavors (such as butyls) actually continue to dissipate, and "bad" flavors (such as hexanols) are retained or increase such that in about eight (8) to 18 months, the food product can be considered to taste "bad."

It is difficult to quantify an exact time period over which fresh flavor is lost, but for the food products of the present invention, including the freshly puffed cereal 134 described herein, it is assumed that fresh flavor can be lost within about seven (7) days or possibly within less than about three (3) to about four (4) days after finish preparation is completed, depending on storage conditions. In one embodiment, the food products are stored under ambient conditions, and consumed before the volatile loss has reached a steady state, which in some embodiments can be within about two (2) to three (3) days.

If the freshly puffed cereal 134 is stored under sufficient pressure, the loss of volatiles can be reduced or even eliminated. Similarly, if the freshly puffed cereal 134 is refrigerated or frozen, the loss of volatiles can be reduced. However, since a refrigerator is typically a humid environment full of aromas and flavors, moisture and flavor transfer can readily occur with food products, such as the freshly puffed cereal 134. Although a freezer can offer a more stable environment, moisture transfer is still a consideration when a food product is removed, due to condensation. Storage of food products in certain types of bags can exacerbate these problems. However, if the freshly puffed cereal 134 is refrigerated or frozen in a barrier container or package, and returned to room temperature inside the barrier package, the freshly puffed cereal 134 will likely retain its fresh flavor an additional few days, possibly up to an additional week or more, depending on several factors, such as storage temperature, humidity level, and so forth. It is possible, however, that starch retrogradation will occur more rapidly at the lower temperatures, which can negatively affect texture and cause staleness. In one embodiment, the puffed food product is provided to a consumer within less than about two weeks or less than about one week or less than about one day or less than about one hour or less than about one minute after having been formed into a puffed food product.

In an alternative embodiment, the puffed food products are served to the consumer in the food service facility several days, weeks or even months after being puffed, depending on storage conditions. In this embodiment, the half-products can be puffed at a location other than the food service facility and shipped to the food service facility as needed or scheduled. The puffed food product can be made available in bulk containers 120 as described above. Additionally, any type of additive and/or topping can also be available in bulk food containers, such that the consumer can obtain their selections in the desired quantities themselves or request service, as described above. The selections can be mixed together in the same container or can be kept separate at the time of purchase, as desired.

In one embodiment, the consumer begins the selection process for either the half-product or a fully puffed food product and associated additives and toppings by completing a survey, such as the health and nutrition survey described in U.S. Provisional Application Serial No. 60/181,282 entitled, "Customized Food Selection, Ordering and Distribution System and Method" (hereinafter "Application 60/181.282") filed on February 9, 2000, which is hereby incoφorated by reference in its entirety. The survey can be completed in any location and in any manner, such as by hand or using any type of computer device, as described in Application 60/181,282. For example, the survey can be completed prior to entering the store by any suitable electronic or non-electronic means. The survey can also be interactive as described in Application 60/181,282, such that recommendations as to food product and food product combinations are provided to the consumer in response to the survey answers. The survey can be connected to the Internet, such as a Web site, but the invention is not so limited.

Any suitable type of user interface can be used, such as the various user interfaces described in Application 60/181,282. In one embodiment, the user interface is available in the food service facility as a touch screen (or keyboard and mouse connected to a monitor), such that the consumer reads and answers the survey questions by touching the appropriate place on the screen (or typing in or clicking on the proper information). In another embodiment, the consumer speaks into a telephone or other voice-activated device to complete the survey.

In response to the survey answers, a recommendation engine produces a recipe that can be constructed for immediate or subsequent sale and delivery. In one embodiment, the consumer selects an option to have the final product delivered to an off-site location. The recommendation engine can be a computer program searching a database as described in Application 60/181 ,282. In an alternative embodiment, the "recommendation engine" is a trained person who uses their skills and knowledge to provide one or more recommendations to the consumer, based on information provided by the consumer with regard to health, taste and nutritional needs and desires. In another embodiment, the recommendation engine is a computer "expert system" or some other means of relating requirements to output. The consumer then picks one or more choices from amongst the recommendations. The recommendations can include healthy choices, tasty choices or a blend of healthy and tasty choices, but do not necessarily need to be labeled as such. The variety of foods, ingredients and combinations can include those described herein as well as those contained in Application 60/181,282. The desired components can be measured manually by the consumer, by food service facility staff or by any suitably trained personnel. Alternately, the measuring can be automated. Similarly, the various components comprising the final product can also be assembled and packaged manually or automatically. For example, each bin or bulk container 120 can be in communication with an automatic measuring/blending and/or packaging machine. In this embodiment, the consumer only needs to essentially "punch in" the desired components using the recommendation engine, and the finished product is produced automatically. The assembly can occur in the vicinity of the user interface or at a nearby location within the food service facility. Packaging can range from single serve to bulk-pack as described in detail herein.

"Ordering" of a food product in this embodiment is essentially comprised of a consumer inputting data to a recommendation engine, receiving recommendations as output, and then choosing a final product or products from the recommendations given. The recommendation engine essentially "links" the consumer's needs and/or desires to one or more "recipes" or food formulations. Such formulations can further include any of the nutritional and health components and nutrient delivery vehicles described in Application 60/181,282. In this way, a unique and customized food product can be delivered directly and immediately to the consumer. In embodiments in which food service personnel is assisting the consumer, the consumer can advise them as to whether the final product is going to be eaten on-site or whether it should be packaged "to go." If the consumer chooses to consume the final product in the food service facility 122, i.e., dine-in 220, the single serving 126 of freshly puffed cereal can be placed in a serving container of suitable size, such as a bowl 130. In the embodiment shown in Fig. 2, toppings 136 have been added to produce a single serving 126 of flavored freshly puffed cereal 140 suitable for dining in. If the consumer chooses to consume his/her food elsewhere, the freshly puffed cereal 134 can be placed in any type of take-out package 218, such as a suitably sized box or bag. In the embodiment shown in Fig. 2, the take-out package 218 is a bag that can hold a single serving 126 of any type of freshly puffed cereal 134 (including flavored 140 and moist/flavored freshly puffed cereal 142). Alternatively, the take-out package 218 can be sized to carry multiple servings. In one embodiment, the take-out package 218 is insulated to keep the freshly puffed cereal 134 warm during transport by the consumer. In another embodiment, the take-out package 218 has a foil liner. In one embodiment, the takeout package 218 can also be used as a serving bowl.

As noted above, additives such as toppings 136 and milk 138 can be added to the freshly puffed cereal 134 as desired. These additives can be applied by food service personnel in response to consumer request or can be applied by the consumer. Toppings 136 and milk 138 can also be packaged for take-out 222. In one embodiment, the toppings 136 and milk 138 are pre-packaged for distribution to the consumer. In one embodiment, the packages also have instructions on how to apply the toppings 136. If the food service facility 122 is not equipped with a puffing device (such as a convection air oven 132) that is capable of puffing the half-product pellets 124 or the consumer otherwise desires to prepare and consume her food at home or work, then the food service facility 122 can sell any quantity of half-product pellets 124 directly to the consumer for the consumer to prepare at home as shown in Figs. 3A and 3B. Fig. 3A shows one embodiment wherein a single serving 126 of one or more types of half-product pellets 124a, 124b and/or 124c (hereinafter "124") is gathered and placed into a take-home package 218. The single serving 126 can then be weighed on a scale 310. Toppings 136 and written instructions 312 on preparing the half-product pellets 124 can also be provided with the package 218 prior to the time the consumer leaves the food service facility 122. In one embodiment, food service facility personnel gather and or weigh the half-product pellets 124 for the consumer. In an alternative embodiment, the consumer gathers and weighs the half- product pellets 124. As noted above, the toppings 136 can also be pre-packaged in single serving quantities, with the packaging having instructions on how to apply the toppings 136. Alternatively, separate written instructions can be given on application of the toppings 136. By providing written instructions 312 for preparation of the half-product pellets 124 and application of the toppings 136, together with allowing the consumer to purchase unpuffed half-product pellets 124, the food service facility 122 is essentially providing the components for a "take- home kit" which the consumer can use to prepare a desired quantity of cereal or snack food at the desired time.

The steps of gathering, puffing, weighing, selecting toppings and picking up instructions can take a minimum amount of time. In one embodiment, the entire process from gathering half-product pellets to selecting toppings and picking up instructions takes less than about ten (10) minutes. In an alternative embodiment, the process takes less than about five (5) minutes. In the time line 316 shown in Fig. 3 A, the entire process takes about two (2) minutes, with the "gathering" step 317 taking about 0.5 minutes, the "weighing" step 318 taking about 0.5 minutes, and the "selecting toppings and picking up instructions" step 320 taking about one (1) minute.

Once the consumer arrives at the desired location, such as home 322 or work, the single serving 126 can be placed or poured into any suitable type of serving container, such as a bowl 130 as shown in Fig. 3B. The single serving 126 can then be prepared into a freshly puffed cereal or savory snack food in a similar manner as was described above for the food service facility 122. The steps of reading the instructions, pouring, puffing, applying toppings and milk, and serving to oneself or to a family member, co-worker, or guest, can take a minimum amount of time. In one embodiment, the entire do-it-yourself process from pouring to serving takes less than about ten (10) minutes. In an alternative embodiment, the process takes less than about five (5) minutes. In one embodiment, the puffing step takes about 0.25 minutes. In the time line 323 shown in Fig. 3B, the entire process takes about 4.5 minutes, with the "reading instructions" step 324 and "pouring" step 326 together taking about one (1) minute, the "puffing" step 328 taking about 0.3 to about two (2) minutes, the "applying toppings and milk" step 330 taking about one (1) minute, and the "serving" step 332 taking about 0.5 minutes.

The process as described in Figs. 3A and 3B can also include other steps that may enhance, alter or simplify the distribution, preparation or consumption of the end product. Furthermore, certain steps may have sub-steps that have not been discussed or shown in Figs. 3A and 3B. For example, the weighing step 318 shown in Fig. 3 A can include the use of any of a number of well-known types of self- service weighing systems. In one embodiment, such a system can include a device that automatically dispenses a label having the correct weight and price information for the half-product pellets 124. Such a label might be dispensed after the consumer has pressed the appropriate button corresponding to the type of half-product pellet he has gathered. Alternatively, the consumer can note the type of half-product pellet 124 he has gathered using supplies located nearby and bring the selected quantity of half-product pellets 124 to personnel who weigh the half-product pellets 124 for the consumer.

Once the half-product pellets have been gathered, weighed and taken away from the food service facility 122, the consumer can store the half-product pellets 124 for an indeterminate length of time before using them, since the half-product pellets 124 have a virtually unlimited shelf life. Such storage capabilities can be of considerable importance during times of food shortages or other emergencies where the food supply is diminished or cut-off for any reason.

An advantage of the present invention is that the consumer can enjoy the flavor, texture and aroma of a freshly prepared grain based snack or beverage. In particular, in certain variations, the consumer can enjoy the eating sensation of the freshly prepared grain based snacks, for example, while still warm from finish preparation.

Another advantage of the present invention is that, if desired, additives can be selected and employed that enhance or supplement the aroma generated during the final heating preparation or flavors added after heating that enhance or compliment the flavor of the finished product.

Still another advantage is that the flavors and aromas will be fresh and have less "loss" than comparable products prepared and distributed in a conventional manner. Conventional distribution methods result in products having less flavor and aroma through loss over extended storage times. In a related benefit, the products are free of undesirable flavors and aromas that can be generated in situ through long-term shelf storage of finished products. Also, the products of the present invention can have lower levels of undesirable and unknown contaminates that can migrate into the product from or through conventional packaging. Still another advantage is that products can be prepared having very particular flavor and/or nutritional profiles. For example, additives can be formulated with particular nutritional features such as enhanced vitamin, mineral or fiber fortification as discussed further in Fig. 9A.

Using the above-described methods of preparation and consumption, the consumer is able to select the exact quantity and type of half-products desired, and the end product can be as portable as the consumer desires. With a wide array of additives (including savory and sweet toppings) available for use either at the food service facility 122 or available in ready-to-go packages, the consumer can customize her particular serving to suit her/his own individual tastes. Since the end product can be consumed shortly after it has been puffed, the consumer is able to enjoy, for the first time, a favorite cereal or snack food in a warm, flavorful, and aromatic condition. Also, since the end product can essentially be eaten as a snack, an entire meal or even a beverage or dessert, the food service facility benefits from an increased volume of traffic during times that are traditionally considered "slow" or "down-time."

HALF-PRODUCT PELLET PRODUCT EMBODIMENTS The half-product pellets can be packaged and puffed in a variety of ways, thus providing the consumer with many choices on the type of "kit" to purchase and the type of preparation method to be used. Such packaging can include written instructions on how to prepare the half-product pellets. The kit can also include toppings and instructions on how to apply the toppings. Single Serving Microwave Puffing Package

Figs. 4A-4D show one embodiment of the present invention comprising a single serving microwave puffing package (hereinafter "microwave package") 410 having instructions 412 on the back for puffing the enclosed half-product pellets 124 in microwave oven. The microwave package 410 can be similar to the bags currently used for popping popcorn in a microwave oven.

It is important to note that the microwave package 410 described herein can also be designed to be a convection air oven package or possibly an air popper package, and the instructions modified accordingly. In one embodiment, the convection air oven package has instructions for opening the package prior to puffing.

The microwave package 410 can be sold individually, or a number of microwave packages 410 can be packaged together in a consumer-sized container 414 such as a box, bag or container, as shown in Fig. 4A. Any number of microwave packages 410 can be packed in the consumer-sized container 414. In one embodiment, the consumer-sized container 414 contains twenty or more microwave packages 410, in another embodiment, there are about 10-15 microwave packages 410. In yet another embodiment, less than about ten (10) microwave packages 410 are packaged together. In the embodiment shown in Fig. 4 A, the consumer-sized container 414 is about 15 cm (about six (6) in) long, about 15 cm (about six (6) in) wide, about ten (10) cm (about four (4) in) deep and holds about five (5) microwave packages 410. In an alternative embodiment, the consumer- sized container is about 2,000 to 5,000 cm³ and holds more than one puffing package. In still other variations, the microwave packages 410 are larger than single serving packages, and the container 414 has about three (3) to six (6) such packages.

The microwave package 410 can be of any suitable shape and size. In one embodiment, it is expandable so that the packages can be shipped as compactly as possible. For added convenience with storage and shipping, the microwave package 410 can also be foldable into one-half or one-third its original size prior to being shipped or packaged in the consumer-sized container 414. In one embodiment, the microwave package 410 unfolds to be about 25 to 35 cm (about 9.8 to 14 in) in length. In this embodiment, the microwave package 410 is about 10 to 13 cm (about 3.9 to 5.1 in) wide, about one (1) cm (about 2.5 in) thick, and can be folded into thirds such that it is only about six (6) to nine (9) cm (about 2.4 to 3.5 in) long. After the puffing process is complete, the microwave package 410 is fully expanded, and can be about five (5) cm (about two (2) in) to about 12 cm (about 4.7 in) thick. The microwave package 410 can hold any suitable amount of half-product pellets 124 depending on whether it is intended as a child-sized serving, a regular single serving or a family-sized serving, and further depending on the size of the half-product pellet 124. In one embodiment, the microwave package 410 holds about 15 g (about 0.5 oz) to about 25 g (about one 0.9 oz) for a child-sized serving, about 30 g (about one (1) oz) to about 70 g (about 2.5 oz) of half-product pellets 124 for a regular single serving, and more than about 75 g (about 2.7 oz) to about 125 g (about 4.4 oz) or more of half-product pellets 124 for a family-sized serving. In another embodiment, the microwave package 410 holds one half-product pellet, which can comprise a single or multiple serving when puffed. In order to preserve freshness and control moisture, the microwave package

410 can also be surrounded by a moisture impermeable or moisture transfer resistant outerwrap 416, such as plastic wrap, which can be clear. The microwave package 410 in Fig. 4B is shown folded in thirds and surrounded in outerwrap 416. Since such folding may hide the instructions on the back of the microwave package 410, it is important that the exposed portion of the microwave package 410 contains information necessary for the consumer to know how to open and use this product. In Fig. 4B, the microwave package 410 states the following information on the front of the package:

"Remove plastic covering. Unfold puffing bag. Read all instructions on back." Once the consumer completes these preliminary steps, a complete set of instructions 412 can be found on the back of the package as shown in Fig 4C.

The instructions 412 should necessarily convey the information necessary to prepare the half-product pellets 124. In one embodiment, the instructions 412 provide only the minimum information necessary, such as the appropriate puffing time and power level. In one embodiment, any necessary cautions or tips are also included in the instructions. In the embodiment shown in Fig. 4D, the "Microwave Puffing Instructions" 412 include precautions to be taken regarding the high temperatures and escaping steam which will be encountered upon puffing and opening, respectively.

The Microwave Puffing Instructions 412 in Fig 4D read as follows:

THIS SIDE UP OPEN THIS END ^■»

MICROWAVE PUFFING INSTRUCTIONS 1. PLACE unfolded puffing bag in center of oven with INSTRUCTION

SIDE UP.

2. PUFF on HIGH for about 15 seconds to four (4) minutes. (Since puffing time will vary depending on wattage of microwave and type of half- product, it is recommended that the timer be set for 15-second intervals the first time this half-product type is puffed in your microwave).

3. STOP microwave when there is only about two (2) to three (3) seconds between puffing.

4. Carefully REMOVE HOT bag from oven and place on heat-resistant surface. 5. OPEN bag, being careful to avoid contact with escaping steam.

6. Immediately POUR CONTENTS into the desired number of bowls.

7. ADD milk (if desired) and APPLY desired topping as directed.

8. SERVE while still warm and ENJOY the awesome and unique taste of your favorite cereal or snack straight from the oven!! DO NOT REUSE BAG OR RE-HEAT UNPUFFED HALF-PRODUCT

This bag not intended for individual sale. U.S. Patent No. x,xxx,xxx THIS SIDE UP OPEN THIS END ^■»

Other examples of the types of instructions 410, which can be used for microwave preparation, are discussed below in Figs. 5B and 8B.

Half-Product Package Forms an Eating Container

Certain types of half-product packaging can be used not only for shipping and puffing the half-products, but for serving the freshly puffed cereal as well. Any number of variations of packaging shapes and sizes can be used, including packages which retain about the same shape during shipping, puffing and eating, packages which need to be expanded by the user prior to puffing, or packages which expand during puffing. As with the microwave package 410 discussed above, the packages that form an eating container, such as a bowl, can be sold individually or a plurality of these packages can be grouped together and sold as a unit to the consumer.

Fig. 5 A is a schematic diagram showing a method of preparing half-product pellets 124 which includes use of a single serving box (hereinafter "box") 510 that is similar in size and appearance to the well-known type of packaging currently used to contain individual or single servings of finished dry cereal. In one embodiment the box is about 12 cm (about 4.7 in) in length, about 7.5 cm (about three (3) in) wide, about 2.5 cm (about one (1) in) thick and contains about 50 g (about 1.8 oz) of half-product pellets. In one embodiment, the box 510 is also liquid-tight so that liquids such as milk 138 can be added without causing leaking. The box 510 can be made from any type of wateφroof material or can be made with a material such as paperboard or cardboard, and lined with a wateφroof material or bag such as suitable thickness of plastic, foil or wax paper (not shown). Any seams that are used to form the box 510 can be sealably bonded so they are liquid-tight.

The box 510 can also be designed for use in a convection air oven. Such a box 510 necessarily needs to be opened prior to puffing. The box 510 can further contain foil or high temperature paperboard. The foil can be used either as the package material or as a liner. In one embodiment, the top of the box or other package is designed to be opened before placing the package inside the convection air oven for about 15 seconds to about two (2) minute or more. The box 510 necessarily has written instructions 512 for puffing as shown in Fig. 5B. The written instructions 512 can be located on any side of the box 510 or can be provided as an insert inside the box 510. One example of the type of written instructions 512 that can be provided is shown in Fig. 5B. In this embodiment, the written instructions 512, which are called "Puff-Secret Instructions," are on the back of the box 510 and read as follows:

HANDLE CAREFULLY: VERY HOT BOX! PUFF-SECRET INSTRUCTIONS:

1. OPEN: Press perforations on front of box and pull back to form flaps.

2. MICROWAVE: Set power on High. Set time for 5 minutes. Place box in center on turntable or floor of microwave.

3. STAY & WATCH: Stop microwave when puffing begins to slow down

PUFF! to about 2 seconds between puffs, (about 1-5 minutes). 4. CAREFULLY REMOVE: Box and contents are hot! Remove carefully from microwave. Set on heat-resistant surface.

5. CUSTOMIZE: Apply frosting as directed and 1/2 cup of milk.

6. SERVE: ENJOY YOUR FRESH, WARM, CRUNCHY CEREAL OR SNACK!!!!

Important Tip: Do not reheat unpuffed half-product or reuse box after puffing has stopped.

The box 510 can be opened by any suitable means before, during or after puffing. In one embodiment, as shown in Fig. 5 A, the box 510 is opened prior to puffing by applying pressure with a finger or utensil to perforations 514 located on the front of the box 510. In an alternative embodiment, the box 510 opens along the perforations during puffing due to pressure from the puffing half-product pellets 124 inside. In another alternative embodiment, the top portion of the box 510 expands during puffing, and is easily opened by the end-user after puffing, when the perforations 514 are pulled apart and/or pressed. In the embodiment shown in Fig. 5 A, the perforations 514 form the shape of a large case "I" such that neither the vertical portion of the "I" nor the top and bottom cross-bars of the "I" extend all of the way to the edge of the box 510. In this way, flaps 516 are formed when the perforated edges are pulled back.

Puffing the pellets 124 in a microwave oven 513 produces freshly puffed cereal 134 as shown in Fig. 5 A. Additionally, frosting 528 and milk 138 can be added to produce moistened flavored freshly puffed cereal 142. In one embodiment, the puffing step takes about 0.25 minutes. In the time line 517 shown in Fig. 5 A, the entire process can take from about three (3) minutes up to about 7.5 minutes, with the "reading instructions" step 518 taking about 30 seconds, the "opening box" step 520 taking about 30 seconds, the "puffing" step 522 taking from about 0.3 minutes up to about five (5) minutes or more, the "applying frosting and milk" step 524 taking about one (1) minute and the "serving" step 526 taking about 30 seconds. Although the instructions 512 discuss (and Fig. 5A shows) the application of frosting 528 and milk 138, it is not necessary to apply either of these additives. Also, any other additives not discussed in Fig. 5A can also be added, as the consumer desires.

The box 510 can be constructed in any suitable manner from any suitable number of pieces. Fig. 6 is a pian view of one embodiment of the box 510 constructed from two separate pieces of material 610 and 612, which are joined by suitable means as shown in the shaded area 614. The larger dashes indicate folding lines and the smaller dashes are the perforations 514 discussed above.

Figs. 7A-7F show an alternative embodiment of a half-product package that is expanded by the consumer to form a bowl. Although the expandable bowl 710 is shown having two (2) overlapping concentric rings, i.e., an outer ring 712 and an inner ring 714, in practice, any suitable number of overlapping concentric rings can be used. Each concentric ring is made from any suitable material, such as moisture-resistant paperboard or plastic, and can be about one (1) cm to about 2.5 cm or more in height. The "wall" comprising the ring is necessarily thick enough so that it remains rigid during use. Each concentric ring is at least slightly smaller in diameter at the bottom than at the top, such that the "wall" of each ring is angled in an outwardly direction. In this way, each progressively larger outer ring is slideable over an adjacent smaller ring, similar to a collapsible-type cup. The innermost ring necessarily has a bottom portion contiguous with the wall portion of the ring, such that an innermost area is formed.

In the embodiment shown in Fig. 7A, the innermost ring is the inner ring 714 and the innermost area is the inner area 716. Fig. 7A shows a cross-section of the expandable bowl 710 in the unexpanded position (with a slight gap shown between the inner ring 714 and outer ring 712 for clarification). The expandable bowl 710 can be packaged so that the half-product pellets 124 are restrained within the inner area 716 during shipping. In one embodiment, a suitable covering or cover 718, such as foil or plastic, can be used for shipping, and then removed prior to (or after) puffing, depending on the puffing method used. Alternatively, the half-product pellets 124 can be packaged in individual serving pouches or bags (not shown) that are opened by the consumer, who then pours the contents into the inner area 716 of the expandable bowl 710 prior to puffing. Fig. 7B is a top view of the expandable bowl 710 with the covering 718 removed. The expandable bowl 710 is expanded by pulling the outer ring 712 in an upwardly direction until the inner ring 714 interferes with this movement. As Figs. 7C shows, after expansion the inner ring 714 and outer ring 712 are still partially overlapping, and the half-product pellets 124 are still contained within the inner area 716, although an outer area 718 has now been created. The half-product pellets (or single pellet) 124 are then puffed using any suitable device and any suitable method of puffing. In one embodiment, the expandable bowl 710 is placed in a microwave oven for about 15 seconds to about five (5) minutes, and can be agitated and/or rotated continuously or periodically, such as one or more times during puffing. In another embodiment, the expandable bowl 710 is placed directly in a convection air oven or a microwave oven/convection air oven device for a suitable length of time.

After the half-product pellets 124 have been puffed, the resulting freshly puffed cereal 134 is now contained within both the inner area 716 and the outer area 718 as shown in Figs. 7E and 7F. It should be understood that many variations are possible with this type of packaging. For example, the expandable bowl 710 can also have a "base" which provides stability and is wider than the largest concentric ring and is contiguous with or attached to the inner ring 714.

The cover 718 can then be secured over the top of the expandable bowl 710 by overlapping it with the "base." In one embodiment the expandable bowl 710 is reusable. In another embodiment, the cover 718 is also reusable, such that any uneaten portion of freshly puffed cereal 134 can be covered tightly to prevent spillage and to preserve freshness.

Multi-Serving Half-Product Package Half-product pellets can also be packaged in multiple serving quantities in any suitable type of packaging. In one embodiment, half-product pellets are packaged in a "cereal box-sized" package (hereinafter "multi-serving package") ranging in size from about 12 cm (about 4.7 in) to about 30 cm (about 12 in) or more in length, about 20 cm (about eight (8) in) to about 36 cm (about 14 in) or more in height, and about 2.5 cm (about one (1) in) to about 7.5 cm (about three (3) in) or more in depth. A multi-serving package for half-product pellets can hold more cereal per package than the same sized package can hold of finished cereal, because the unpuffed pellets are much smaller and denser than finished cereal. As noted above, half-products are about one-third to about one-fifth, down to about one-tenth or less the size of finished cereal. As a result, the traditional multi- serving package can hold about two times (2x) to about five times (5x), up to about ten times (lOx) or more pellets per unit volume. In one embodiment, the multi- serving package holds about 250 g (about nine (9) oz) to about one (1) kg (about 2.2 lbs) or more or about 1.5 to about four (4) L of half-product pellets. The consumer can conveniently pour out an individual serving of half-product pellets, in a similar manner to the way finished dried cereal is poured from boxes. Alternatively, the consumer can pour out a larger-sized serving, such as a family- sized serving and prepare multiple servings at one time. In another embodiment, only one "half-product" is provided in a package. This half-product can be a very large half-product as defined herein, and can comprise a multi-serving (or single serving) finished product.

Fig. 8A shows one embodiment of a multi-serving package (or cereal box- sized package) 810 having half-product pellets 124 contained within, inside a package liner 811. On the back of the multi-serving package are puffing instructions 812. In the embodiment shown in Fig. 8B, puffing instructions 812 are given for a variety of home appliances, including a microwave oven, a conventional hot air popcorn popper (including a cyclonic popper), deep fat fryer and convection air oven. A variety of other appliances or any combination of home appliances or home puffing devices can also be used to prepare the half-product pellets 124, as discussed in greater detail below in Figs. 13-18, including, but not limited to, a conventional oven, stove top, broiler, gas grill, a microwave/convection air oven combination, an appliance designed specifically for puffing pellets, and so forth. The simplest of instructions 812 can include directions to pour a desired quantity of pellets into any suitable bag, add a small amount of a moisturizing agent (such as oil), such as one (1) to two (2) squeezes or more from a squeeze bottle, close the bag and shake the contents before placing in a suitable puffing device. In this way, moisture which otherwise would be lost during puffing is retained, and any desired coatings will stick to the surface of the final product. In an alternative embodiment, the oil can be added to the finished product together with any desired additive, such as a powdered additive intended to coat or glaze the final product.

The Puffing Instructions 812 shown on the multi-serving package 810 in Fig. 8B read as follows:

PUFFING INSTRUCTIONS

HOT AIR POPPER 1. Add about 25 -125 g (about 1 - 4 oz) of half-product.

2. Remove snap-on lid from cover and place cover on top of hot air popper.

3. Turn popper on.

4. Puff until there is only about 2-3 seconds between puffs (about 15 seconds to 2 minutes).

5. Replace snap-on lid onto cover.

6. Turn cover over and dig in.

DEEP FAT FRYER 1. Place about 500 ml (about 2 cups) of oil in deep fat fryer and preheat for about 3 minutes on HIGH.

2. Add about 50 g (about 1.8 oz) of half-product, being careful not o splash hot oil out of fryer. 3. Leave deep fat fryer on HIGH and puff for about 0.25 - 3 minutes, or until most of the half-product appears to have puffed and are a toasty-brown in color.

4. Scoop out freshly puffed cereal with a slotted spoon so that excess oil can drain out. (Alternatively, or in addition, line a container with paper towels and place the freshly puffed cereal on top of the paper towels so that excess oil can be absorbed).

CONVECTION AIR OVEN

For single serving: 1. Puff about 50 g (about 1.8 oz) of half-product in convection oven for about

20 seconds or until most half-product has puffed. 2. Remove from oven and add desired toppings. MICROWAVE OVEN

1. Pour desired amount of half-product into a microwave-safe container or bag.

2. Add oil as directed in the chart below and shake for at least 30 seconds or until all half-product is coated with oil. 3. Pour contents in microwave safe bowl and puff on HIGH according to the chart below, rotating once during puffing.

4. Puffing is complete when there are only about 2-3 seconds between puffs.

Milk is typically added to provide moistness and flavoring after the pellets have been puffed. However, milk or milk products can also be added as a topping before or during puffing. Milk can include any type of cream or cream product, 5 whole milk, skim milk, or other milk such as 1% or 2%, buttermilk, sour milk, chocolate milk, acidophilus milk, powdered milk, and so forth.

A variety of other additives can also be applied before, during or after puffing. As noted above, these additives can be applied alone or with a suitable carrier substance. Additives are typically added to improve and/or change the

10 appearance and/or taste and/or content of the final product. However, additives can also include aromatic substances that change or enhance the aroma of the half- product pellets during and after puffing. Additives can be any of a number of flavors, including, but not limited to, sweet, semi-sweet, bitter, sour and so forth. In one embodiment, the additives are combined with the half-product pellets or freshly

15 puffed cereal in such a way that they are uniformly distributed on the final product, so that a RTE product enriched in the desired way is obtained. In one embodiment, the additives and half-product pellets are exposed to the source of energy together, with or without a suitable carrier. Suitable carrier substances include, but are not limited to, animal and vegetable fats and oils, sugars, salts, and so forth, or a

20 combination thereof. Additives can include a predetermined amount of nutrient and health additives such as vitamins, minerals, fiber, anti-oxidants, encapsulated biologically active components, dietary supplements, and special supplements such as probiotic bacteria sprinkles, (e.g., lactobacillus (or acidophilus)), inulin, calcium carbonate, energy, protein or satiety additives, nutriceuticals, and so forth, including other similar health-enhancing additives. In U.S. Patent No. 5,747,080 to Lemke, et al., which is hereby incoφorated by reference, a process for producing popped grain products enriched with vitamins, mineral nutrients and/or trace elements is taught. If sufficient quantities of these types of additives are used together with the novel half-product pellets of the present invention, a consumer can meet the minimum daily requirement for these essential elements by consuming a certain amount of a freshly puffed food product.

Fig. 9A shows one embodiment of a multi-serving package having one or more containers of toppings or coatings included within (hereinafter "package with toppings") 910. Any suitable type and quantity of flavoring additives, or mixtures of additives, such as any of the nutrient and health additives noted above, any type of topping, flavoring, glaze, or coating can be included in the package with toppings 910, such as colorings, honeys, nuts, nut pieces, sugars (e.g., sucrose, fructose, dextrose) in various forms (e.g., brown sugar, white sugar, confectionery sugar, etc.), sugar substitutes, marshmallows, gelatins, ground or powdered spices (e.g., cinnamon, nutmeg, cardamom, various salts, etc.), herbs, dried whole fruits (e.g., coconut, raisins, etc.), fruit parts, dried fruit products, fruit products (e.g., fruit syrups, etc.), flavorings (including meaty, vegetable, cheese, spicy, fruit, caramel, butterscotch, malt, peppermint, and other flavorings found in products such as ice cream, sherbets, yogurts, soda drinks, phosphates, malts, milk shakes, frostings, and so forth) which can be packaged as dried or powdered flavorings, other powdered toppings (including powdered fruits, milks, milk fractions, juices, cheeses, etc.), aromatic substances, candies, chocolates and chocolate products, flavored frosting, including any type of taste-enhancing additives, and so forth. The toppings can be applied in any suitable way including being sprayed, sprinkled, squeezed, poured, spooned on, and so forth. The toppings can be applied before, during or after puffing, depending on the particular type of topping, and the particular tastes and/or dietary requirements of the end user. In the embodiment shown in Fig. 9A, the toppings 528a and 913 are enclosed within the "package with toppings" 910 in an internal toppings compartment 911 as shown. Although any suitable number of internal toppings compartments can be used, the internal toppings compartment 911 shown in Fig. 9 A is divided into two (2) sections, with each section holding one type of topping. The toppings shown in Fig. 9A include sprayable vanilla frosting 528a and powdered cheese 913.

In addition to puffing instructions, 812, the "package with toppings" 910 can also have toppings instructions 916. The Toppings Instructions 916 for applying the vanilla frosting 528a and powdered cheese 913 are shown in Fig. 9B and read as follows:

TOPPINGS INSTRUCTIONS

Powdered

1. Place puffed cereal in a bag. 2. Coat puffed cereal with 5-10 g of oil.

3. While shaking bag, sprinkle on powdered topping.

4. Mix thoroughly.

5. Enjoy!! Sprav

1. Lift frosting can from packaging and remove tab.

2. Hold can upside down and spray desired amount onto freshly puffed cereal or snack. 3. Mix thoroughly.

4. Enjoy!!

(For an alternative dining experience, apply toppings to half- product prior to or during puffing!!)

A multi-serving package can be designed in any suitable way, including having one or more spouts for pouring out one or more types of half-product pellets contained within. The package can also include one or more dividers so that a variety of pellet types can be kept separated, but still be conveniently packaged together in one package. In the embodiment shown in Fig. 9C, the multi-serving package (hereinafter "pourable package") 920 has two (2) spouts and one (1) internal divider 922 so that the first and second half-product pellet types, 124a and 124b, respectively, are packaged and stored separately. When ready, a user can open a first pour spout 924 and pour out a desired amount of the first half-product pellet type 124a. Similarly, the user can then open a second pour spout 926 and pour out a desired amount of the second half-product pellet type 124b. The two pellet types, 124a and 124b, respectively, can be poured into the same serving container to provide a unique mixture of flavor, texture and shape. Alternatively, the user can pour the two half-product pellet types, 124a and 124b, respectively, into separate serving containers to serve separate individuals. Toppings can also be included inside the pourable package 920 or packaged in an external toppings compartment 927, as shown in Fig. 9C. In the embodiment shown in Fig. 9C, squeezable strawberry-flavored frosting 926a, squeezable blueberry-flavored frosting 926b, and colored coconut sprinkles 930 are packaged on top of the pourable package 920 in the external toppings compartment 927 located on top of the pourable package 920.

In addition to puffing instructions, 812, the pourable package 920 can also have squeeze and sprinkle toppings instructions 928. The Squeeze and Sprinkle Toppings Instructions 928 for applying the strawberry and blueberry-flavored squeezable frostings, 926a and 926b, respectively, and the coconut sprinkles 930, are shown in Fig. 9D and read as follows:

SQUEEZE AND SPRINKLE TOPPINGS INSTRUCTIONS

1. Remove desired tube of frosting from packaging and open by tearing or cutting where marked and squeeze desired amount onto freshly puffed cereal or snack. 2. Remove container of coconut sprinkles and apply liberally to freshly puffed cereal or snack.

(For an alternative dining experience, apply toppings to half- product prior to or during puffing!!)

The ability to package the half-product pellet products of the present invention in so many varied ways creates unlimited choices for the consumer to customize a particular serving to suit his/her tastes as well as his/her dietary requirements. The consumer is now able to choose from single serving packages or multi-serving packages, and can use any number of puffing appliances and methods to prepare the half-product pellets. Some puffing methods can even be adapted to use over an open fire, providing an additional option of preparing the half-product pellets in a fireplace or over an open campfire. Furthermore, the convenience of the packaging in which the package forms a bowl allows the consumer to easily take along individual servings of a favorite cereal while traveling away from home.

HALF-PRODUCT PELLET DISTRIBUTION As noted previously, half-product pellets can be distributed to the consumer using various distribution systems. One system of distribution involves distributing half-product pellets to the retail market in consumer-sized packages or kits. This system of distribution typically involves the consumer transporting a quantity of half-product pellets away from the retail market, and preparing and consuming the end product at home, work, or any location that can be inside or outside, including at a campsite or picnic area, and so forth. In an alternative embodiment, the consumer can have kits delivered to any location, such as their home, by a variety of methods. In another alternative embodiment, half-product pellets can first be shipped in bulk to a puffing facility located close to retail markets, remote from the manufacturing plant, where the half-product pellets are prepared for consumption according to local tastes. Production can be controlled based on demand so that the operator in the particular facility (such as a grocery store, puffing facility or any other food service facility), has a suitable inventory on hand at all times.

Half-Product Pellet Distribution from Manufacturing Facility to Grocery Store Fig. 10A shows one embodiment of a system of half-product pellet distribution comprising transporting raw materials 1002 to a factory 1004 where various types of half-product pellets 124 are produced. The half-product pellets 124 can be delivered to the factory 1004 by any suitable means of shipment, including by air, rail, ship, truck and so forth, or by any combination of shipping means. In the embodiment shown in Fig. 10A, a tractor-trailer truck 1006 is used to transport the raw materials 1002. The factory 1004 can be any suitable type of mass production facility capable of manufacturing bulk quantities of half-product pellets 124.

The half-product pellets 124 can be packaged in a suitable consumer package. Suitable types of consumer-sized packages or "kits" include, but are not limited to, single serving packages, such as the microwave package 410, the "box" 510 (which forms a bowl), the expandable bowl 710 discussed above, or any type of package intended for use in a puffing device such as a convection air oven. Consumer packages can also include any type of larger package, such as the multi- serving package 810 and the package with toppings 910, also discussed above. For simplicity, only the multi-serving package 810 with instructions 812 is depicted in Figs. lOA and lOB.

Any suitable number of multi-serving packages 810 can be packaged together in a pellet carton 1008. In one embodiment, about six (6) to twelve (12) multi-serving packages are packaged together. In another embodiment, more than twelve (12) multi-serving packages are packaged together in a pellet carton 1008. In the embodiment shown in Fig. 10B, about six (6) multi-serving packages 810 are packaged in one pellet carton 1008.

Referring again to Fig. 10A, the pellet cartons 1008 are distributed to a retail outlet, such as a grocery store 1010. In the embodiment shown in Fig. 10A, the pellet cartons 1008 are transported to the grocery store 1010 on a tractor-trailer truck 1006. The multi-serving packages 810 can then be displayed on display shelves 1012, and can be located in an area where toppings 136 are sold. The consumers 1014 can then select one or more multi-serving packages 810 and toppings 136, if desired. "Consumers" 1014 can include any number of end users, such as children, co-workers, other members or guests of the consumer's household, and so forth.

The consumer(s) 1014 can transport their selected purchases, including the multi-serving package 810, to their home 1016 (or business or other location) by using a vehicle 1018 or traveling by foot, either carrying the multi-serving package 810 or by placing it in or on some type of wheeled cart or wagon. Alternatively, the consumer can use public transportation to travel to and from the grocery store or any other suitable means such as bicycle, motorcycle and so forth, depending on the local infrastructure. The consumer 1010 can then use any suitable appliance and method for preparing the half-product pellets 124, including any device having a puffing capacity less than about two (2) L (about 0.5 gal). The freshly puffed cereal 134 shown in Fig. 10A was prepared by pouring the desired amount into a bowl 130 and using a convection air oven 132 for a suitable length of time, according to the instructions 812 on the multi-serving package 810. Although any type of freshly puffed cereal 134 can be prepared, the freshly puffed cereal 134 in Fig. 10A is a snack product which is large enough to be eaten as a hand-to-mouth snack.

Any suitable amount of half-product pellets 124 can be shipped from the factory 1004 on a daily basis. In one embodiment, about 500 kg (about 1,100 lbs) of half-product pellets 124 are shipped daily to the grocery store 1010. In another embodiment, about 1,000 kg (about one (1) ton) or more of half-product pellets 124 are shipped daily. The food service facility or grocery store 1010 can be located any suitable distance from the factory 1004 and deliveries can take any suitable amount of time. In one embodiment, the grocery store 1010 is less than about 20 km (about 12 miles) from the factory 1004 and the half-product pellets 124 are in transit less than about 15 minutes. In an alternative embodiment, the grocery store 1010 is about 50 km (about 31 miles) to about 150 km (93 miles) or more from the factory 1004 and the half-product pellets 124 are in transit ten (10) minutes to two (2) hours or more. In another alternative embodiment, the factory 1004 is located anywhere in the world, and shipping can take one (1) to three (3) days or more. In one embodiment, the grocery store 1010 is located in an area that is close to established shipping channels, so that transportation costs and time can be kept to a minimum. Any number of deliveries can be made to the grocery store 1010 as often as necessary. In one embodiment, deliveries are made one (1) or more times daily. In another embodiment, deliveries are made biweekly, weekly, monthly or less frequently. In yet another embodiment, the half-product pellets 124 are stored for up to a year or more, and shipped to the use point as needed. The end user or consumer 1014 can also be located any suitable distance from the food service facility, such as the grocery store 1010, and round trip travel time from the consumer's home 1016 (or work, etc.) to the grocery store 1010 can take any suitable amount of time. In one embodiment, the consumer 1014 lives or works in the same area as the grocery store 1010, and it takes about five (5) minutes or less to travel to the store. In another embodiment, the consumer 1014 lives or works less than about two (2) km (about 1.25 miles) from the grocery store and it takes less than about 15 minutes to travel between home 1016 (or work) and the grocery store 1010. In yet another embodiment, the consumer 1014 lives or works about two (2) km (about 1.25 miles) to about 20 km (about 12.5 miles) or more from the grocery store and it takes 15 minutes to one (1) hour or more to travel from home 1016 (or work) and the grocery store 1010. In one embodiment, the grocery store 101 is located in an area that is convenient for the consumer 1014 to reach depending on the modes of transportation available. Half-Product Pellet Distribution from Manufacturer to Distributor

Kits having various types of half-product pellets and instructions can also be distributed through any type of delivery service, mail order company (including Internet-based businesses), and the like. As shown in Fig. 11 A, a delivery service 1102 can use one or more delivery trucks 1104 having a selection of half-product pellet products or kits, such as microwave packages 410 (or convection oven packages or air popper packages), which are packed in pellet cartons 1108. Additives such as toppings 136 (not shown) can also be provided. The half- product pellet products have a virtually unlimited shelf life and do not need to be frozen prior to delivery, although they can be frozen, if desired, as can the toppings 136 and associated products. The delivery trucks 1104 can deliver in a particular neighborhood 1109 at regular intervals, similar to currently available frozen food home delivery services. Since the delivery truck 1104 returns to the neighborhood 1109 at regular intervals, there is no need for the consumer 1014 to contact the delivery service 1102 in order to receive delivery of half-product pellet products. However, the consumer 1014 can contact the delivery service 1102, if desired, to place special orders or large orders, or simply to ensure that there will be adequate supply of the desired product when the delivery truck 1104 is in their neighborhood 1109. Additionally, the consumer 1014 may choose to contact the delivery service 1102 if he/she was not at home 1016 when the delivery truck 1104 arrived, and request that a special trip be made to his/her home 1016. In one embodiment, the delivery service 1102 also provides (by mail or door-to-door delivery) information 1106 for the consumer 1014 to use, having details on products (including toppings), prices, and means for contacting the delivery service 1102, if needed. The information 1106 can be delivered to the consumer 1104 through any suitable means as described below, including, but not limited to, door-to-door delivery, through conventional postal service means, via E-mail, facsimile, on a web site, and so forth.

Another shop-at-home system for half-product pellets and toppings involves the consumer 1014 initiating an order for a kit, such as a microwave package 410 (or air popper package or convection air package) from a supplier or distributor 1108 using any number of communication methods. The supplier 1108 can be a specialty supplier that distributes only half-product pellet products, or it can be a general supplier that handles products for a variety of businesses. The consumer can use any wired or wireless connection or communication means. The consumer 1014 can obtain information 1106 about the products in a variety of ways, such as through reading a written catalog, viewing product choices on a computer monitor either through the Internet via modem (including accessing a supplier's web site), or using a supplier-provided CD-ROM, computer disk, or any other type of computer software means. Other sources of information, include, but are not limited to television infomercials, radio advertisements, video or audio tapes, and so forth, to include any type of medium and means through which information can be conveyed. Again, the information 1106 can provide details on only half-product pellet products, or it can be information from a general suppler who sells a variety of other products from a number of businesses. In the embodiment shown in Fig. 1 IB, the consumer 1014 can use the

United States mail service 1110, telephone 1112, computer 1114, facsimile 1116 or a private delivery service 1102 (as described in Fig. 11 A) to place the order. The computer 1114 not only allows the consumer 1014 to access a supplier's web site, but also allows the consumer to use e-mail to place an order. The consumer 1014 can further pay for this order via the computer using credit or debit card means. Other means of communication include, but are not limited to, electronic data interchange, cable, and so forth.

In response to the order from the consumer 1014, the supplier 1108 can ship the requested products either directly to the consumer's home 1016 as shown in Fig. 1 IB, or to a nearby distributor of half-product pellets, such as a store in a local mall. The supplier 1108 can use any available means of transportation, including their own delivery trucks 1104 as shown in Fig. 1 IB, the U.S. mail, or any of a number of private delivery services such as Federal Express®, United Parcel Service®, and so forth. The supplier 1108 can be located virtually anywhere in the world. Orders can be processed and delivery received on the same day or within two (2) days to a week or more.

Half-Product Pellet Distribution from Manufacturer to Puffing Facility

Fig. 12 shows one embodiment of a half-product pellet distribution system that is initially similar to the distribution system described in Fig. 10A. Raw materials 1002 are transported to a factory 1004 where half-product pellets 124 are produced. Any suitable means of shipment can be used, including air, rail, ship, truck and so forth, or any combination of shipping means. In the embodiment shown in Fig. 12, a tractor-trailer truck 1006 is used to transport the raw materials 1002 to the factory. The factory 1004 can be any suitable type of mass production facility capable of manufacturing bulk quantities of various types of half-product pellets 124. Production of the half-product pellets 124 can also be adjusted to meet local tastes.

Typically, it is not necessary to add preservatives to the half-product pellets 124. In one embodiment, however, suitable preservatives are added to the half- product pellets 124 prior to being packaged or boxed. For example, anti-oxidants can be added to the cereal dough during manufacturing in order to keep fat in the dough from becoming rancid. Although anti-oxidants are not typically considered to be a type of preservative, they do serve to minimize degradation of the half- product pellets 124. In another embodiment, the half-product pellets 124 are packed in a special container that is flushed with suitable gasses that help to preserve the half-product pellets 124. In one embodiment, the half-product pellets 124 are shipped directly to the consumer in this type of container, or the container is otherwise made available to the consumer anywhere the half-product pellets are sold or distributed.

In one embodiment, the half-product pellets 124 are packaged in bulk quantities in any suitable type of container such as bags, barrels, boxes, crates and so forth. In the embodiment shown in Fig. 12, the half-product pellets 124 are packaged into sacks 216, such as the 25 kg (55 lbs) bags described above in Fig. 2. The sacks 216 are then shipped by any suitable means to puffing facilities 1210 around the world. Fig. 12 shows shipments of the sacks 216 by air, water and land using aiφlanes 1212, ships 1214 and tractor-trailer trucks 1006, respectively. In another embodiment, any combination of these methods of transportation, as well as any other method of transportation, such as by rail, can be used in order to deliver the sacks 216 to the desired location.

The half-product pellets 124 are prepared at the puffing facilities 1210 according to local tastes using a variety of recipes. The resulting freshly puffed cereal 134 can then be placed in suitable bulk containers, such as the five (5) L bulk containers 212 described in Fig. 2 for shipment a limited distance to smaller local markets, such as grocery stores 1010. Any conventional or non-conventional method of transportation can be used to deliver the bulk containers 212 a relatively short distance to the grocery stores 1010 as shown in Fig. 12. Such methods include, but are not limited to, shipment by truck, foot, boat, pack animal, jeep, helicopter and so forth, depending on the infrastructure of the particular country or region. In the embodiment shown in Fig. 12, delivery trucks 1120 such as those described in Fig. 11 can be used. In one embodiment, the bulk containers 212 arrive at the grocery store 1010 while the puffed cereal 134 is still fresh.

The puffing facility can add one or more additives, such as toppings (not shown) to the freshly puffed cereal 134, or can add additives before or during puffing. Alternatively, or in addition, the grocery stores 1010 can provide additives for consumers to purchase. The consumer can then purchase a desired amount of freshly puffed cereal 134 from the bulk container 212. In one embodiment, individual servings 126 are placed in suitable take-home bags 218, as shown in Fig. 12. In an alternative embodiment, any suitable portion of freshly puffed cereal 134 is placed in a take-home container. In another alternative embodiment, the grocery store 1010 has a seating area where the consumers can sit and consume the freshly puffed cereal 134. It should be understood that any type of food service facility can offer this product to consumers, and the freshly puffed cereal 134 can be eaten on-site or taken out.

The puffing facilities 1210 can be located any distance from the factory 1004. In one embodiment, the puffing facilities 1210 are in relatively close proximity to the local grocery stores 1010 so that the time from preparation to consumption is minimized. In a preferred embodiment, the time from preparation to consumption is less than about two (2) hours. In an alternative embodiment, the time from preparation to consumption is about two (2) hours to about two (2) days. Although the freshly puffed cereal 134 can be delivered several days after it is puffed, it is preferable to deliver it while it is still fresh. If preservatives have been added during production, the puffed cereal can stay fresh for an extended period. If necessary, additional steps can be taken to preserve the freshness of the puffed cereal 134, such as keeping it under an adequate pressure or possibly keeping it frozen until it is delivered to the grocery store 1010. This type of distribution system provides a unique and efficient way to distribute needed foodstuffs to consumers in a manner well-adapted to third world countries, where shipping RTE products long distances is problematic. At the same time, these consumers can enjoy a fresher and more desirable end product.

The types of half-product pellets 124 that are shipped can also be customized for the particular location. In many countries, it is the larger products, including HTM snacks, which are most popular. Any suitable amount of various types of half-product pellets 124 can be shipped to each puffing facility 1210 at regular intervals or on an as-needed basis. In one embodiment, about 20 kg (about 44 lbs) to about 200 kg (about 4400 lbs) or more are shipped daily to each puffing facility 1210, and each puffing facility 1210 produces and ships from about two (2) L (about 0.5 gal) to about 100 L (about 26 gal) or more to each grocery store 1010.

HALF-PRODUCT PELLET PUFFING DEVICES Half-product pellets can be puffed in a variety of commercial devices, including, but not limited to, vending machines, batch or continuous commercial puffing machines, or other commercial conventional puffing equipment. Half- product pellets can also be puffed in any conventional at-home device, such as a microwave, hot air popper, deep fat fryer, high-speed convection oven, microwave/convection oven, conventional oven, fry pan, saucepan, Dutch oven, wok, grill, broiler, toaster, toaster-oven, or any other suitable small appliance designed to rapidly heat particulate matter, including an appliance designed primarily for puffing half-product pellets at home. In one embodiment, the apparatus has the capability of meeting the different time-temperature puffing profiles of the various types of half-product pellets. In one embodiment, it takes less than about five (5) hours to puff the pellets. In some embodiments, the half- product pellets can be prepared almost "instantly," i.e., in less than about 15 to 60 seconds, down to about 15 -20 seconds or less. In one embodiment, the apparatus is adaptable for use as a consumer or commercial device. The apparatus can also include a computer control system having instructions for storing, displaying and processing recipe information necessary to operate the apparatus.

Commercial Half-Product Pellet Puffing Devices

As noted above, any of the known methods for preparing unpuffed half- products for consumption can be used. Traditionally RTE cereals have been puffed using deep fat frying, although more recently, other methods producing products lower in fat are more commonly used, such as "gun puffing" or "fluid bed puffing" with hot air. Microwave energy is also now commonly used to prepare the pellets, as described in the patents to Schwab, Borek and Whalen, supra, as well as U.S. Patent Nos. 5,338,556; 5,198,255; 5,196,218 and 5,182,127 to Schwab et al., all of which are hereby incoφorated by reference. In his patents, Schwab discloses various methods of puffing, toasting, tempering or improving the stability of puffable pellets for RTE cereals or cereal-based snack half-products. In an alternative embodiment, a commercial apparatus designed solely for puffing pellets is used, such as the device described in U.S. Patent No. 4,878,422 to McCullough, et al. In one embodiment, half-product pellets prepared from dough are puffed in a device specifically designed to puff low-shear pellets. Such a device can comprise a suitable type of housing rigidly mounted on a suitable frame having suitable drying means, toasting means, enrobing means and grinding means. In one embodiment, the device has a suitable metering device for metering the amount of pellets and/or toppings that are added to the process. In an alternative embodiment, the device also has a suitable system controller that receives input from these and other necessary devices.

The commercial apparatus can either be owned or leased by the facility that is using it. In one embodiment the apparatus is a puffing system that is flexibly adapted to puff a variety of types of half-products. In one embodiment, the puffing systems have adequate ventilation through suitable hoods, exhaust vents, fans and so forth, so that puffing odors are controlled. In an alternative embodiment, the apparatus is readily transportable from one locale to another. Continuous Devices. In one embodiment, the apparatus comprises a puffing system having variable speeds to accommodate a wide range of product puff times as the product is carried through the puffing unit on a continuous basis.

Fig. 13 shows one embodiment of a continuous commercial method for puffing half-product pellets 124a-e (hereinafter "124"). A variety of types of half- product pellets 124 of varying shapes, sizes, texture and content can be dispensed from a pellet dispensing bin 1310 through any suitable type of transport line 1312 into one end of a rotating drum 1314 where they are puffed in a "puffing" step 1316. The rotating drum 1314 is kept at an elevated temperature sufficient to adequately puff the half-product pellets 124 within. In one embodiment, the temperature inside the drum is about 120 °C to about 315 °C or more. Although Fig. 13 shows five (5) different types of half-product pellets 124, in practice, any suitable number of types of half-product pellets 124 can be used depending on the particular facility, customer demand, and so forth. The rotating drum 1314 can be non-corrosive and can be made from any suitable material, such as stainless steel, plastic, ceramic, and so forth. The rotating drum 1314 can also be any suitable size to accommodate the needs of the particular facility. In one embodiment, the rotating drum 1314 is about 30 cm (about one (1) ft) to about 60 cm (two (2) ft) in length and has a diameter of about 15 cm (0.5 ft) to about 30 cm (one (1) ft) or more. In another embodiment the rotating drum 1314 is about 1.8 m (about six (6) ft) or more in length and has a diameter of about 30 cm (one (1) ft) to about one (1) m (about 3.3 ft) or more.

The half-product pellets 124 can be rotated in the rotating drum 1314 for any suitable length of time. In one embodiment, the half-product pellets 124 are rotated for about 30 seconds to about three (3) minutes or more and the rotating drum 1314 rotates about five (5) to about 20 or more revolutions per minute. The continuous process can be operated at any desired speed. In one embodiment, about ten (10) kg/hr (about 22 lbs/hr) to about 100 kg/hr (about 22 lbs/hr) or more of half-product pellets are processed. In the embodiment shown in Fig. 13, freshly puffed cereal 134 emerges from the opposite end of the rotating drum 1314. The freshly puffed cereal 134 can then pass through an "optional flavoring" step 1316, and can have flavorings added, such as the toppings 136 previously discussed, to produce flavored freshly puffed cereal 140 as shown. The toppings 136 can be contained in one or more topping dispensing bins 1316 as shown in Fig. 13. The flavored freshly puffed cereal 140 (or freshly puffed cereal 134 if no toppings have been added) can then pass through an "optional reheat" step 1318 prior to delivery 1320 and consumption 1322. In one embodiment, the time between the puffing step 1316 and the consumption step 1322 is less than about one (1) minute. In one embodiment this time period is between about one (1) minute and about two (2) days. The end product in this process is not a packaged product, but is served to consumers as needed in the desired amounts which can range from about 0.1 kg (about 3.5 oz) to about one (1) kg (about two (2) lbs) or more. If larger end products are produced, the desired amount of food may be only one (1) or more pieces.

Batch. Half-product pellets can also be puffed by a variety of batch methods. Fig. 14 is a schematic diagram showing two different types of batch processes. Both processes begin with the dispensing of half-product pellets 124a-e (hereinafter "124") as discussed above. Specifically, a variety of types of half- product pellets 124 of varying shapes, sizes, texture and content can be dispensed from a pellet dispensing bin 1310 through any suitable type of transport line 1312 into one end of a batch bin 1410. Although Fig. 14 shows five (5) different types of half-product pellets 124, in practice, any suitable number of types of half-product pellets 124 can be used depending on the particular facility, customer demand, and so forth. In one embodiment, only one of each type of pellet 124 is used Heat Chamber. The first batch process starts when a suitable amount of half- product pellets 124 in the batch bin 1410 is released into a heating chamber where they are heated in a "pre-heating" step 1412. The heating chamber is kept at a high enough temperature to adequately "pre-process" the half-product pellets 124 prior to entering the puffing chamber where they are expanded in a "puffing" step 1414. In one embodiment, the heating chamber is heated to between about 150 °C to about 200 °C. The heating chamber can be heated by any known type of heating device or means, according to the desired conditions. The puffing chamber can puff the pellets 124 using any suitable source of energy as discussed above, such as thermal energy. In one embodiment, the temperature in the puffing chamber is about 120 °C to about 315 °C. In another embodiment, the puffing chamber has an optional temperature adjustment control so that when heat is desired, the temperature can be controlled to be at the desired range, such as between about 120 °C to about 315 °C. In one embodiment, both the heating chamber and the puffing chamber are insulated to reduce heat loss. Both chambers are designed to hold a suitable amount of food. In one embodiment, the chambers hold from at least one half-product pellet 124 to about 0.5 kg (about 1.1 lbs) of half-product pellets 124, up to about 50 kg (about 110 lbs) or more of half-product pellets 124. Freshly puffed cereal 134 emerges from the puffing chamber after a suitable time period. In one embodiment, the half-product pellets 124 are puffed for about 15-20 seconds to about three (3) minutes or more. The puffing process can also include periodic agitation of the half-product pellets 124. The resulting freshly puffed cereal 134 can then pass through an "optional flavoring" step 1416, and can have flavorings added, such as the toppings 136 previously discussed, to produce flavored freshly puffed cereal 140. The toppings 136 can be contained in one or more topping dispensing bins 1316 as shown in Fig. 14. The flavored freshly puffed cereal 140 (or freshly puffed cereal 134 if no toppings have been added) can then pass through an "optional reheat" step 1418 prior to delivery 1420 and consumption 1422. In one embodiment, the time between the puffing step 1414 and the consumption step 1422 is less than about one (1) minute. In one embodiment, this time period is between about one (1) minute and about two (2) days. The end product in this process can be packaged and served to consumers as an individual serving of RTE freshly puffed cereal. Alternatively, the end product can be used to fill or supplement bulk containers as needed or can be served to consumers as needed in the desired amounts.

Deep Fat Fryer. In the alternative batch process shown in Fig. 14, half-product pellets 124 enter a frying chamber (rather than a heating chamber) to be puffed in a "frying" step 1424 where the half-product pellets 124 are fried in a bath of hot oil. The frying chamber can be designed to preserve the quality of the oil for successive batches. The half-product pellets 124 can be moved through the system by mechanical or oil flow means until it withdrawn from the oil and passed to a "removing surface oil" step 1428 which is designed to remove oil by any suitable means. After this step, the freshly puffed cereal 134 can pass through all of the steps discussed above, including the optional flavoring step 1416, the optional reheat step 1418, delivery 1420 and consumption 1422.

Any suitable amount of freshly puffed cereal 134 can be produced. In one embodiment, about one (1) ml (about one piece) to about 50 L (about 13 lbs) is produced, although, if desired, up to about five (5) half-product pellets to about one (1) kg of freshly puffed cereal 134 can be made. In one embodiment, only a single serving, of freshly puffed cereal 134, such as about 30-60 g (one (1) to two (2) oz ) is produced in each batch. Such a device can be used to make any suitable type of end product. In one embodiment, "pasta-type" puffed snacks, i.e., having a screw or spiral shape, are made from pasta half-product pellets. In another embodiment, the amount of fryer fat in the final product is minimized. Vending Machine. Another type of batch process can take place inside of a vending machine 1510 as shown in Fig. 15 A. The vending machine 1510 can be operated via any suitable means and has suitable mechanical and electrical means to operate properly. The vending machine 1510 can be operated in the same manner as conventional vending machines, such that there is a money interface 1509 through which bills or change can be placed and a conventional coin return 1514. In an alternative embodiment, the vending machine 1510 is designed to receive money electronically, either via credit or debit card.

In one embodiment, the vending machine 1510 comprises a power supply 1511 , a system controller 1513, a data bus interface 1515, and a system unit 1517. In this embodiment, the system controller 1513 comprises a computer processor, nonvolatile memory, input device and monitor. The system controller 1513 can be coupled to various sensing devices to monitor certain variables or physical phenomena, process the variables, and output control signals to control devices to take necessary actions when the variable levels exceed or drop below selected or predetermined values. Such amounts are dependent on other variables, and may be varied as desired by using the input device of the controller. The non- volatile memory may comprise a disk drive or read only memory device which stores a program to implement the above control and store appropriate values for comparison with the process variables as is well known in the art.

In a further embodiment, the system controller 1513 may comprise a machine coupled to a control panel 1519. Buttons can be provided on the control panel 1519 so that the consumer has a number of choices available. Such buttons can include those shown in Fig. 15 A, including pellet buttons 1518, topping buttons 1520, an "add milk" button 1522, and a "money control system" which operates the money interface 1509 and coin return 1514. Devices which receive signals from the system controller 1513 include all of the devices which are required to operate the batch process 1516 described in Fig. 15B. In one embodiment, the system unit 1517 comprises all of the devices or machinery, including consumer interface features, needed to operate the vending machine 1510. These devices are discussed in Fig. 15B and can include a bowl-dropper, conveyor, pellet dispenser, heater, cooler, topping and milk dispenser, carrier device, and end-product dispenser. Other devices that can be controlled by the system controller 1513 include toaster, enrober, grinder, and so forth.

Assuming the power supply (or energy supply) 1511 is already turned on, the batch process 1516 is activated when a consumer deposits a specific amount of money (or inserts a suitable magnetic card, such as a credit or debit card, etc.) in the money interface 1512. This can be the exact amount of money required, or in excess of the amount of money required. In the latter case, the consumer will have change returned through the coin return 1514 after the final product has been dispensed. In the embodiment shown in Fig. 15 A, the cost is $1.00 for cereal with one (1) topping 136. The consumer can then press a half-product pellet button 1518 to select a desired type of half-product pellet 124, a topping button 1520 to select a desired topping 136, and an "add milk" button 1522 to select milk 138. Although Figs. 15A and 15B only show three different half-product pellet buttons 1518, namely "A," "B," and "C," in practice, any number of half-product pellet buttons 1518 corresponding with an equal number of half-product pellet types can be offered. Similarly, there can be more than three topping buttons 1520, namely "1," "2" and "3." In one embodiment, four (4) or more types of half-product pellets and up to fifteen (15) or more types of additives are offered. In an alternative embodiment, the consumer can select more than one type of half-product pellet 124 and more than one type of topping 136, and in one embodiment, at additional cost. In an alternative embodiment, one or more of the half-product pellet buttons 1518 correspond to a blend or mixture of types of half-product pellets 124.

The batch process can be any suitable type of batch process for producing a desired final product in a vending machine 1510. In the embodiment shown in Fig. 15B, the batch processl516 starts when a bowl 130 drops from a bowl drop device 1524 onto a moving conveyor 1526 as shown in Fig. 15B. The bowl 130 is moved under the area of the half-product pellets 124 and the selected type of half-product pellet 124 is dispensed. Fig. 15B shows an embodiment in which the "B" pellet button 1518 has been pressed, causing an individual serving 126 (about 25-100 g or more) of the "B" type half-product pellets 124 to be dispensed from the "B" dispenser 1528 only. The individual serving 126 then moves into the heating area 1530 until freshly puffed cereal 134 is produced. In the embodiment shown in Fig. 15B, the freshly puffed cereal 134 then passes to a cooling area 1532 having a fan 1534 so that the individual serving 126 of freshly puffed cereal 134 can cool down slightly before the toppings 136 are added. In the embodiment shown in Fig. 15B, the "1" topping button 1520 was selected, causing an individual serving of the topping 136 in the "1" topping dispenser 1536 to be dispensed onto the freshly puffed cereal 134 to produce flavored freshly puffed cereal 140. Since milk 138 was not chosen in the embodiment shown in Fig. 15B, the individual serving 126 of flavored freshly puffed cereal 140 moves along to a suitable carrier 1538 which slowly lowers the end product 140 into the dispenser 1540, where the consumer can pick it up.

The batch process 1512 can take any suitable amount of time. In one embodiment it takes from about less than 20 seconds to about four (4) minutes or more from the time the consumer deposits her money, until the end product enters the dispenser 1540.

In an alternative embodiment, multiple servings are prepared at the same time. The multiple servings can be one puffed piece to about 0.5 kg (about 1.1 lbs), up to about one (1) kg (about 2.2 lbs) or more.

In another alternative embodiment, the vending machine 1510 is not used to puff the half-product pellets 124, but dispenses a variety of kits as describe herein, which the consumer can then prepare in a nearby puffing device, such as a convection air oven or hot air popper. Such vending machine/puffing apparatus combinations can be located virtually anywhere people congregate, such as aiφorts, railroad stations, hospitals, schools, subways, entertainment facilities such as movie theatres, and so forth. Consumer Appliances for Puffing Half-Product Pellets Hot Air Popper. Fig. 16 is a simplified schematic drawing of a method of puffing half-product pellets 124 at home using a hot air popper 1610 in accordance with one embodiment of the present invention. A conventional hot air popper 1610 can be used, or a hot air popper specifically designed for puffing half-product pellets as described herein. In one embodiment, the hot air popper 1610 replicates the industrial process by providing the required rate of heat transfer. The hot air popper 1610 can be any suitable type of hot air popper used to pop popcorn. This can include a cyclonic-style hot air popper in which rotating arms move the contents. In one embodiment, the hot air popper is an electric hot air popper having about two (2) to three (3) arms which sweep the contents of the puffing chamber during puffing. In another embodiment, a counter-top consumer-sized electric hot air popcorn popper made by The West Bend Company in West Bend, Wisconsin is used.

In the embodiment shown in Fig. 16, a certain quantity of half-product pellets 124 is poured into a chamber area 1612 of a cyclonic air popper, such as about 50 g (about 1.8 oz). The half-product pellets 124 can be from any type of single-sized or multi-sized package, such as the pourable package 920 discussed above. It is not necessary to add any moistening agent, such as oil, prior to cooking, although this can be done, if desired. A cover 1614 can then be placed on top of the hot air popper 1610. In the embodiment shown in Fig. 16, a small amount of oil 1612, such as about 15 ml (about one (1) Tablespoon), is added to the top of the cover 1614, together with a topping 136, which can be one or more toppings. The oil 1612 essentially serves as a "glue" to help the topping 136 better adhere to the freshly puffed pieces. In another embodiment (not shown), the oil 1612 and toppings 136 are added after the pellets 124 have been puffed, and the contents of the puffing chamber 1613 shaken for a time period, which is sufficient to allow the toppings to coat or adhere to a suitable number of the freshly puffed pieces. The top of the cover 1614 can have a suitable number of holes 1621 as shown, to allow the toppings 136 and oil 1612 to pass through into the chamber area 1613 during puffing. When the hot air popper 1610 is turned on, rotating arms 1615 begin to turn as shown in Fig. 16. The rotating arms 1615 can be any suitable type of agitator such as a paddle or stirrer that operates continuously or intermittently to move the contents. The hot air popper 1610 can remain on for a suitable amount of time, according to the instructions. In one embodiment, the half-product pellets 124 are puffed and stirred for about 15-20 seconds to about three (3) minutes or more, depending on the quantity and/or type of half-product pellets 124 being puffed.

When puffing is complete, a suitable lid 1616, such as a plastic lid, can be secured onto the top of the cover 1614, so that excess toppings 136 and oil 1612 do not leak out when the cover 1614 is turned over. After the cover 1614 is turned over, the resulting flavored freshly puffed cereal 140 can be eaten as a snack directly from the cover 1614 or placed into individual serving containers. Alternatively, if toppings 136 have not yet been added, or if additional additives are desired, these ingredients can be applied at this time. The flavored freshly puffed cereal 140 (or freshly puffed cereal 134) can also be ground at this point so that it can be admixed or blended into a beverage or other chilled or frozen snack as discussed herein.

In one embodiment, the process of puffing the pellets 124 takes a minimum amount of time. In the time line 1618 shown in Fig. 16, the entire process can take less than about three (3) minutes up to about seven (7) minutes or more with the "reading instructions" step 1619 and the "adding pellets" step 1620 together taking about one (1) minute, the "placing cover" step 1622 taking about 15 seconds, the "adding oil" step 1624 and "adding topping" step 1626 taking about 30 seconds, the "puffing" step 1628 taking from about 15 seconds to about four (4) minutes, and the "turning over cover and adding lid" step 1630 taking less than about 30 seconds. In another embodiment, the entire process takes less than about one (1) minute.

Microwave. The use of a conventional microwave oven to prepare the unique half-product pellets of the present invention has been discussed herein. Any of the aforementioned methods for puffing half-product pellets in microwaves, including those described in Scwhan, et al., supra, can be applied to consumer home appliances. In one embodiment, the apparatus is one that provides adequate pressure for a sufficient period of time so that the pellets are puffed thoroughly and uniformly. Whalen, supra, describes a microwave heating process for half-products which is especially adapted for consumers to use. It should also be understood that the conventional "at-home microwave" can also be the type of microwave oven made available for consumers to use at food service facilities. In one embodiment, the pellets are heat-treated with suitable additives with or without suitable carriers for about 30 seconds to about five (5) minutes or more with microwaves at about 400 to about 1500 watts.

Tumbler. Any suitable type of at-home apparatus designed specifically for rapid heating of parti culates can be used. Fig. 17 shows a method of puffing half- product pellets 124 at home which involves use of a unique counter-top apparatus called a "heat-and-tumble" pellet puffer 1710 (hereinafter "tumbler"). The tumbler 1710 can come with instructions 1711 on how to use the device. In one embodiment, there are also one or more recipes on how to prepare various types of half-product pellets 124. An individual serving 126 of about 50 g (about 1.8 oz) of half-product pellets 124 can be added to the tumbling can 1712. In the embodiment shown in Fig. 17, half-product pellets 124 are poured into the tumbling can 1712 from the pourable package 920. It is not necessary to add any moistening agent at this point, although one can add such an ingredient, such as a small, but suitable amount of oil to the tumbling can 1712. In the embodiment shown in Fig. 17, no moistening agent is added to the tumbling can 1712. After the half-product pellets 124 have been added, a tumbler lid 1714 can then be securely placed on top of the tumbling can 1712. In the embodiment shown in Fig. 17, the tumbler lid 1714 has a small extension 1716 from the center, which allows it to engage a rotating mechanism (not shown) in the tumbler 1710 and to be connected to a heat source inside the tumbler 1710.

The tumbler 1710 can be powered by any suitable means. The power supply 1717 can be from any suitable source of energy such as a small generator, a normal power grid system, and so forth. In one embodiment, the tumbler 1710 is powered with batteries or a car adapter so that the consumer can use the tumbler 1710 anywhere they travel. In the embodiment shown in Fig. 17, the tumbler 1710 has a power cord 1717 connected to either alternating current (AC) or direct current (DC) and is operated under standard voltage. The tumbler 1710 can be turned on with a suitably located power switch 1718, or can simply be activated when connected to the power source, and can also have a variety of controls for controlling the heating, puffing and timing of the puffing process. In the embodiment shown in Fig. 17, the tumbler 1710 has a rotation dial 1720 for adjusting the revolutions per minute of the tumbling can 1712, a temperature dial 1722 for controlling the temperature inside the tumbling can 1712, and a timer 1724 for controlling the length of time the tumbling can 1712 is rotated. In one embodiment, the tumbling can 1712 is first secured in the tumbler

1710 and connected to the heating and rotating means by any suitable means, such as through the extension 1716 on the lid 1714. In one embodiment, the tumbling can 1712 itself can be preheated to the desired temperature, prior to adding the half-product pellets 124, by turning the temperature dial 1720 to the desired setting. The temperature dial 1720 can have specific temperature settings, or can simply be labeled with one or more settings, such as "low," "medium," and "high." An indicator light 1726 can light up when the tumbling can 1712 is up to temperature. In this embodiment, the user the half-product pellets 124 at this time, turns the rotation dial 1720 to the desired setting, and sets the timer 1724 for the desired length of time.

Half-product pellets 124 can be heated and rotated for as long as is necessary to puff the half-product pellets 124. In one embodiment, the half- product pellets are rotated for less than about 15-20 seconds at less than about 125 °C, at less than about ten (10) revolutions per minute. In another embodiment the half-product pellets 124 are rotated for about 15 seconds to about five (5) minutes or more at about 125 °C to about 315 °C or more, at about 10-40 revolutions per minute or more.

Once the tumbling action is completed, the tumbling can 1712 can be removed from the tumbler 1710 taking suitable precautions to avoid direct contact with the heated tumbling can 1712. In one embodiment, the tumbling can 1712 is adequately insulated so that no such precautions are necessary. In another embodiment, a suitable oven mitt or hot pad is used to remove the tumbling can 1712. The lid 1714 can then be removed (with precautions, if necessary) to reveal a full tumbling can 1712 of freshly puffed cereal 134 as shown in Fig. 17. At this point, any desired additives and a "gluing" agent, such as oil, can be added, and the end product can be consumed directly from the tumbling can 1712. If additives and oil are added in this manner, the lid 1714 can then be re-secured to the tumbling can 1712 and the contents shaken to ensure adequate coverage of the additive. Alternatively, the contents of the tumbling can 1712 can be placed into one or more serving bowls, can be ground, topped with other additives in the manner described, added to other food products, and so forth.

In one embodiment, the process of puffing the pellets takes a minimum amount of time. In the time line 1724 shown in Fig. 17, the entire process can take more than about two (2) minutes up to about seven (7) minutes or more with the "reading instructions" step 1726 taking about 30 seconds, the "adding pellets" step 1730 taking about 30 seconds, the "placing lid" step 1732 taking about 15 seconds, the "puffing" step 1734 taking from about 15 seconds to about 4.5 minutes, and the "removing tumbling can" step 1736 and "removing lid" step 1738 together taking less than about 30 seconds.

In an alternative embodiment, the tumbling can 1712 can also toast the half- product pellets 124 either manually or automatically at the desired time, by providing a suitable amount of radiant heat. In another alternative embodiment, the tumbling can 1712 also has grinding means so that the finished product can be finely ground for use as a topping or admixed with a liquid to produce a moist food product, such as a hot or cold beverage, frozen product, and so forth. It should be noted that any of the aforementioned embodiments for making the products described herein can include a grinding step and mechanical means for grinding. Any of the methods and products discussed herein can include reducing the size of the freshly puffed food product. In one embodiment, the size of the freshly puffed food product is reduced by grinding it to any fineness desired, and adding the ground food product to any type of liquid to produce a moist food product. Further, any of these methods and products can also include admixing the puffed food product with any type of edible liquids, semi-liquids, frozen or partially frozen liquids, etc., without being ground in any manner. Such liquids include, but are not limited to any type of beverage at any temperature, such as water, flavored waters, sodas, dairy products (including cultured dairy products), fruit and vegetable juices and purees, carbonated beverages, teas, any type of coffee and coffee drinks (e.g., latte, mocha, etc.), cocoa drinks, as well as any other type of liquid or semi-liquid products, such as soups, yogurts, ice creams, sherbets, frozen yogurts, kefir, as well as various combinations of these liquids. Any of these moist food products can be served warm, hot or cold. In one embodiment, the liquid is frozen and the ground product is applied as a topping, or is added to the liquid prior to freezing.

Whether the freshly puffed cereal is ground or not, the moist food product produced by admixing with liquid can have a consistency ranging from a fluid having a viscosity of at least one (1) cenitpoise to a paste having a viscosity of about 10,000 centipoise or more if exposed to a sheer rate of about 500 sec^"1. The viscosity is adjustable through adjusting the concentration of the freshly puffed cereal in the liquid and/or altering the processing the conditions of the half-product pellets and/or adjusting the particle size of the freshly puffed cereal. In one embodiment, at least a portion of the liquid or semi-liquid has a temperature of less than about 5 °C.

The various moist food products described (and any of the products described herein) can be supplemented by adding any of the additives noted above. In one embodiment, the final product is a mixture still having pieces of the freshly puffed cereal that are not finely ground. In an alternative embodiment, the final product is a blended product such that all of the pieces of the freshly puffed cereal as well as any additional additives have been finely ground and blended with a liquid or semi-liquid food product, to produce any number of products, such as a chilled or semi-solid beverage (e.g., milk shake, malt, smoothie, etc.), or frozen treat or snack on a stick (e.g., Popsicle, fudgsicle), and so forth. In another alternative embodiment, the final product is a blended food product that includes meat.

In addition to the one or more recipes that may come with the cereal apparatus 1712, various cook book-like instruction books can also be available for sale at bookstores, supermarkets, over the Internet, such as on web sites, in magazines, and so forth. The tumbler 1710 can also come in a variety of sizes so that the consumer can select the size (or sizes) which best suits their needs, similar to the varying sizes of coffee makers, bread makers, and deep fat fryers.

Pellet Puffer. Fig. 18 is a schematic diagram of a pellet puffer 1810 that has drying means 1812, toasting means 1814, enrobing means 1816 and grinding means 1818. The drying means 1812 necessarily heats the half-product pellets 124 using any of the conventional methods of heating, thus causing the half-product pellets 124 to puff or expand to produce freshly puffed cereal 134. The toasting means 1814 provides radiant heat and/or conduction heating which involves heat transfer from the exterior of the piece inward to produce toasted freshly puffed cereal 1820. In one embodiment, the toasting means 1814 is designed to avoid scorching of the half-product pellets 124. In one embodiment, the toasting method described in U.S. Patent No. 5,196,218 to Schwab et al., supra, can be used. The enrobing means 1816 coats the freshly puffed cereal 134 with a coating such as a wet sugar coating solution to produce a coated/toasted freshly puffed cereal 1822. The grinding means 1818 grinds the coated/toasted freshly puffed cereal 1822 to produce grounded/toasted/coated freshly puffed cereal (hereinafter "ground cereal") 1824. This ground product can be used in beverages or as toppings, as described above. In one embodiment, the pellet puffer 1810 has a limited volume of less than about one (1) L (about one (1) quart) and can produce ground cereal 1822 in less than about 30 seconds. In another embodiment, as shown in the time line 1826, the entire "puffing" step 1828 which produces ground cereal 1822, as described above, is produced in about 30 seconds to about five (5) minutes or more from the time the half-product pellets 124 are added. In another embodiment, ground cereal is produced in more than five (5) minutes up to about five (5) hours or more. As with the other consumer devices described herein, the pellet puffer 1810 can of varying sizes, and can be packaged with instructions. Further, the pellet puffer 1810 can also be packaged with recipes. Vacuum System. Puffing can also occur if a substantial vacuum, such as less than about one (1) Torr, is applied to the half-product in a suitable vacuum chamber. Since applying a vacuum alone would likely rupture the starch granules, causing the half-product to burst, the use of a vacuum can be combined with use of another energy source. In one embodiment, heat can be applied prior to or concurrent with application of the vacuum in an amount sufficient to cause the half-product to soften to its glass transition temperature. Typical glass transition temperatures range from about 40 °C to 140 °C, depending on the amount of sugar, which is present in the half-product. It is likely that, once softened, the half- product can puff in the presence of a vacuum almost instantly. Control System

Any of the aforementioned commercial or consumer devices or any other suitable type of half-product puffing apparatus can include a computer control system having instructions for storing, displaying and processing recipe information necessary to operate the apparatus. Such an apparatus can have means for heating and cooling, means to agitate or rotate the ingredients, and means to activate and deactivate any dispensers for liquids and powders. The means to heat and cool can include a temperature-measuring component for measuring the temperature of the apparatus throughout the puffing process. The control system can have at least all of the features described herein in relation to the vending machine 1510, including, but not limited to, a system controller, a data bus interface, and a system unit. In one embodiment, the device has a minimum number of "buttons" for the operator to choose from in order to begin a pre-programmed process. In this embodiment, the operator need only add the required ingredients according to a chosen recipe, press the appropriate buttons and wait. Shortly thereafter, the end user can enjoy the final product with no further action required on their part, other than to remove the puffed cereal from the apparatus. In one embodiment, the device can also include a "delayed start" feature allowing the consumer to add ingredients when convenient, and then set a timer on the device to begin puffing the pellets at a pre-selected time, such as early morning. For example, the consumer can load and set the device in the evening, and wake the next morning to the aroma of puffing cereal or freshly puffed cereal. Alternatively, the operator can individually vary the chosen recipe if desired before or during the puffing process, and can even add new recipes to the computer control system using suitable data entry means. This type of device or "pellet puffer" is similar to consumer bread makers, including programmable bread makers, and in one embodiment uses similar electronic and mechanical means. Therefore, any person, even those who possess little or no puffing skills, can now puff a flavorful and unique customized cereal or cereal-based snack with the press of a button.

CONCLUSION The present invention provides a revolutionary new way in which to distribute, select, prepare and consume cereals, cereal-based snacks and beverages. By providing the consumer with access to half-product pellets and the means to puff them, the consumer now has the ability to choose an individually desired method of preparation at a time that is convenient. Furthermore, by using various recipes and combinations of pellets and toppings, the consumer can now fully customize a single serving of cereal to suit tastes and/or dietary needs. The end result is a fresh product, with all the taste and aromatic advantages of freshly baked bread or freshly toasted toast. Such freshly puffed cereals and snacks are far superior to boxed cereals and snacks since they are fresher, crispier, tastier and more aromatic.

The consumer essentially has a nearly infinite selection of cereal and snack products from which to choose ranging from healthy and light snacks to hearty meals. He can pick the type of grain (including, but not limited to, wheat, corn, rice, oat, whole grain, bran, rye, barley, soy, combinations of these grains, etc.), the form of the product (flakes, puffs, shreds or finely ground, etc.), the quantity (breakfast, lunch, snack, etc.), flavorings, nutrient and health additives, fresh particulates (such as sliced bananas, strawberries, dried fruits, nuts, and so forth), method of consumption (in a bowl, with or without a spoon, or in a glass), the temperature (hot, warm or cold), base beverage, if applicable, and so forth.

Additionally, by offering this type of product in food service facilities, such as fast-food restaurants, businesses can now experience increased business at times that would otherwise considered "down times." Excess inventory is also not a problem as the pellets have a virtually unlimited shelf life, since they do not crumble and are easy to keep fresh.

Consumers in countries such as China and Siberia can also enjoy this unique product. By having local puffing facilities use their labor to prepare and ship the puffed cereal and snacks, it is now possible to provide, for the first time, freshly puffed cereals and cereal-based snacks to even the remotest area of the world for the cost of labor delivery only.

Examples of well-known cereals which can now be prepared by the consumer using the system and method of the present invention include, but are not limited to, Wheaties®, Cinnamon Toast Crunch (CTC) Grahams®, Golden Grahams®, all of the various types of Chex® cereals, all of the various types of Cheerios®, such as Honey-Nut Cheerios® (a sugar coated whole grain oat flour cereal in the form of rings having a nut constituent in the cereal base), Apple Cinnamon Cheerios®, etc., and so forth. Other products can include Team

Cheerios®, which is a blend of puffed ring shaped RTE cereal pieces of three types of cereal grains, namely, corn, barley and wheat (i.e., a blend of corn based rings, of barley based rings, and of wheat based ring pieces), and so forth.

Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. For example, consumers can choose to buy in bulk at a food service facility, or have bulk quantities delivered to their home. Since the product has a virtually unlimited shelf life, the consumer can choose to purchase a one (1) to two (2) year supply or more. Alternatively, a high-intensity ultra-violet light can possibly be used as the means for puffing. Any of the puffing devices described herein can further include a suitable pressing device to allow consumers to use the puffed food product, together with any additives desired, to make customized granola bars of any shape and size. Alternatively, the pressing device can be sold as a separate apparatus. Additionally, the entire system, as described herein, can be owned or leased by the owner of the food service facility or a new type of nationwide franchise can be developed with margins as high or higher than gourmet coffee houses.

All publications, patents and patent documents are incoφorated by reference herein, as though individually incoφorated by reference. The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the scope of the invention.

Claims

WHAT IS CLAIMED IS:

1. A partially cooked half-product that expands to produce an expanded food product when exposed to a source of energy, wherein the expanded food product is consumable while still freshly expanded, further wherein the half- product is formed from an at least partially cooked dough containing moisture that expands to a vapor phase when exposed to the source of energy.

2. The half-product according to claim 1 wherein the dough is cereal dough that is not highly worked, further wherein the dough is formed into the unexpanded half-product at a temperature of between about 40 °C and 110 °C.

3. The half-product according to claim 1 wherein the source of energy is a continuous puffing device or a batch puffing device, wherein the batch puffing device expands a single serving or more of the unexpanded half-product.

4. A half-product comprised of one or more half-products especially adapted to puff in a batch puffing device to produce a puffed food product, wherein the half-product contains cooked starch and moisture that is converted to steam during puffing, further wherein the half-product is puffed in a low power device of less than about five (5) kW to 50 kW in less than about 30 seconds to three (3) minutes.

5. The half-product according to claim 1 or 4 wherein one or more types of expanded half-products are located in a food service facility, further wherein a unique formulation of expanded food products, toppings and additives is recommended to the consumer by a recommendation engine located in the food service facility, the recommendation based on health, nutrition and taste information provided to the recommendation engine by the consumer.

6. The half-product according to claim 5 wherein the consumer makes a selection from the recommendations provided and the selection is measured, combined and packaged manually or automatically.

7. A food product comprising: one or more half-products in a package, wherein the package contains one or more servings of half-products; and instructions for puffing the one or more half-products in a batch puffing device to produce a puffed food product, the instructions located on or in the box.

8. The food product according to claim 7 wherein the instructions include adding a moisturizing agent to the half-product prior to, during or after puffing and also agitating the half-product at least once during puffing.

9. The food product according to claim 7 wherein the package also includes toppings and instructions on how to apply the toppings, further wherein the toppings are sprinkled, squeezed, sprayed, poured or spooned onto the food product before, during or after puffing.

10. The food product according to claim 9 wherein the toppings include nutritional additives selected from the group consisting of vitamins, minerals, biologically active components, probiotic bacterias, herbs, colorings, fibers, anti- oxidants, nutriceuticals, dietary supplements, aromatic substances and flavorings and mixtures thereof.

11. The food product according to claim 7 wherein the half-product is puffed while still in the package.

12. The food product according to claim 11 wherein the package forms an eating container for the puffed product, the eating container comprising a bowl or a box.

13. The half-product according to claim 1 or 4 or 7 wherein the unexpanded half-product can be expanded or puffed to about two (2) times to about ten (10) times its original size, further wherein the unexpanded half product has a moisture content ranging from about eight (8) to 15%, a density ranging from about 0.7 to 1.5 g/cc and is substantially free of a topical coating before being expanded or puffed.

14. The half-product according to claim 3 or 4 or 7 wherein the batch puffing device is a consumer device that causes rapid heating and depressurization of the half-product, the batch puffing device selected from the group consisting of a hot air popper, deep fat fryer, microwave oven, vacuum device, convection air oven, or a device custom-designed for puffing half-products.

15. The half-product according to claim 1 or 4 or 7 wherein the expanded or puffed food product is consumed or served within about one to three days of being expanded or puffed.

16. The half-product according to claim 15 wherein the expanded or puffed food product is consumed or served while still warm from being expanded or puffed.

17. The half-product according to claim 16 wherein the half-product is a snack pellet or cereal pellet having a substantially flat shape or a three-dimensional shape, each pellet weighing between about 0.1 and 0.5 grams.

18. The half-product according to claim 1 or 4 or 7 wherein the puffed or expanded food product is mixed or blended with additives in liquid or semi- liquid form to form an admixed food product, moist food product or a blended food product, wherein the additives are selected from the group consisting of water, flavored waters, dairy products, kefirs, juices, sodas, coffees, yogurts and teas, further wherein the blended food product is a cold beverage, frozen snack, semi- solid beverage, frozen snack on a stick or a hot fluid cereal and the moist food product has a consistency ranging from a fluid to a paste and is served frozen, chilled, warm or hot.

19. The food product according to claim 18 wherein the additives are flavoring additives selected from the group consisting of fats, salts, honeys, cheeses, frostings, powdered food products, nuts, nut pieces, sugars, sugar substitutes, candies, marshmallows, gelatins, spices, fresh fruits, dried fruits, fruit products, vitamins, minerals, encapsulated biologically active components, nutriceuticals, dietary supplements, anti-oxidants, fibers, probiotic bacteria sprinkles, inulin, calcium carbonate, energy additives, protein powders, powdered milk fractions satiety additives, flavorings, herbs, colorings, aromatic substances, chocolates and chocolate products, and combinations thereof.

20. A kit, comprising: a puffing package having one or more servings of half-products inside; and the package labeled with instructions on puffing the half-product in a puffing device to produce a puffed food product.

21. A kit according to claim 20 wherein the puffing device is a home puffing device, further wherein the kit also includes toppings and instructions on how to apply the toppings.

22. A method of preparing, distributing and consuming a puffed food product, comprising the steps of: puffing at least one half-product made from a dough to produce a puffed food product; and providing the puffed food product to a consumer while the puffed food product is still freshly puffed.

23. A method of preparing, distributing and consuming a food product, comprising the steps of: providing one or more bulk containers, each containing at least one half-product, the half-product made from a dough; gathering one or more half-products from the bulk containers; puffing the half-product by exposing the half-product to a source of energy at a level and rate sufficient to cause the half-product to expand to produce a puffed food product; and serving the puffed food product to a consumer while the puffed food product is still freshly puffed.

24. The method according to claim 22 or 23 wherein the dough is at least partially cooked, is not highly worked and is formed into the half-product at a temperature of between about 40 °C and 110 °C.

25. The half-product according to claim 23 wherein the source of energy is a continuous puffing device or a batch puffing device, wherein the batch puffing device expands a single serving or more of the half-product, further wherein the steps of gathering, puffing and serving take less than ten minutes.

26. A method of preparing, distributing and consuming a puffed food product, comprising the steps of: puffing one or more half-products in bulk quantities to produce a puffed food product; displaying the puffed food product in bulk quantities; and packaging a take-out quantity of the freshly puffed food product in a food container for transport and consumption.

27. The method according to claim 26 further comprising: a consumer, completing a health and taste survey; the consumer submitting the survey to a recommendation engine; and the consumer selecting one or more unique formulations of puffed product, toppings and additives recommended by the recommendation engine based on information provided by the consumer in the survey.

28. A method of preparing, distributing and consuming a puffed food product, comprising the steps of: providing one or more bulk containers, each containing a different type of half-product; gathering one or more single servings of half-products from the bulk containers, according to a selection made by a consumer; placing the half-product in a take-out package; the consumer preparing the half-product at another location, the preparing resulting in a freshly puffed food product; and the consumer eating the freshly puffed food product at another location.

29. A method of preparing, distributing and consuming a puffed food product, comprising the steps of: obtaining a package of one or more half-products, the package of a certain size or less; puffing a single serving of the half-product in a hot air oven.

30. The method according to claim 22 or 23 or 26 or 28 or 29 further comprising supplying or applying food product toppings.

31. The method according to claim 30 further comprising supplying a set of instructions for the consumer to pick up, the instructions having information on preparing the half-product and applying the toppings, wherein the toppings include nutritional additives selected from the group consisting of vitamins, minerals, biologically active components, probiotic bacterias, herbs, colorings, fibers, anti-oxidants, nutriceuticals, dietary supplements, aromatic substances and flavorings and mixtures thereof.

32. The method according to 22 or 23 or 26 or 28 or 29 wherein the half-product can be expanded or puffed to about two (2) times to ten (10) times its original size, further wherein the half-product has a moisture content ranging from about eight (8) to 15% and a density ranging from about 0.7 to 1.5 g/cc.

33. The method according to claim 22 or 23 or 26 or 28 or 29 wherein the half-product is cooked in a batch puffing device selected from the group consisting of hot air popper, deep fat fryer, microwave oven, vacuum device, convection air oven or a device custom-designed for puffing half-products.

34. The method according to claim 33 wherein the expanded or puffed food product is consumed or served within about one to three days of being expanded or puffed.

35. The method according to claim 34 wherein the expanded or puffed food product is consumed or served while still warm from being expanded or puffed.

36. The method according to claim 22 or 23 or 26 or 28 or 29 wherein the half-product is a snack pellet or cereal pellet having a substantially flat shape or a three-dimensional shape, each pellet weighing between about 0.1 to 0.5 grams.

37. The method according to claim 36 wherein the puffed or expanded food product is mixed or blended with additives in liquid or semi-liquid form to form an admixed food product, moist food product or a blended food product, wherein the liquids are selected from the group consisting of water, flavored waters, carbonated liquids, dairy products, kefirs, juices, sodas, coffees, yogurts and teas, further wherein the blended food product is a cold beverage, frozen snack, semi-solid beverage, frozen snack on a stick or a hot fluid cereal and the moist food product has a consistency ranging from a fluid to a paste and is served frozen, chilled, warm or hot.

38. The method according to claim 37 wherein the additives are flavoring additives selected from the group consisting of fats, salts, honeys, cheeses, frostings, powdered food products, nuts, nut pieces, sugars, sugar substitutes, candies, marshmallows, gelatins, spices, fresh fruits, dried fruits, fruit products, vitamins, minerals, encapsulated biologically active components, nutriceuticals, dietary supplements, anti-oxidants, fibers, probiotic bacteria sprinkles, inulin, calcium carbonate, energy additives, protein powders, powdered milk fractions satiety additives, flavorings, herbs, colorings, aromatic substances, chocolates and chocolate products and combinations thereof.

39. The method according to claim 37 wherein the additives are nutritional additives selected from the group consisting of vitamins, minerals, encapsulated biologically active components, nutriceuticals, dietary supplements, anti-oxidants, fibers, probiotic bacteria sprinkles, inulin, calcium carbonate, energy additives, protein powders, powdered milk fractions, satiety additives and mixtures thereof.

40. The method according to claim 22 or 23 or 26 or 28 or 29 wherein the puffing step takes less than about 30 seconds to three (3) minutes to complete.

41. The method according to claim 40 wherein the puffed food product is a puffed cereal or snack.

42. The method according to claim 41 wherein the puffed food product is size-reduced.

43. The method according to claim 22 or 23 or 26 or 28 wherein the half-product is puffed at a food service facility, further wherein the consumer eats some or all of the puffed food product at the food service facility.

44. A method of preparing, distributing and consuming a puffed food product, comprising the steps of: manufacturing bulk quantities of half-products at a mass production facility; packaging half-products in packages of a certain size or less; and labeling the packages with instructions for puffing one or more servings of the half-products in a hot air popper, convection air oven or other home-puffing device having a puffing capacity less than a certain volume.

45. The method according to claim 44 including distributing the packages to one or more food service facilities wherein the packages are consumer- sized packages, further wherein a consumer transports one or more packages away from the food service facility and prepares the half-products in accordance with instructions on the package.

46. A method of preparing, distributing and consuming a puffed food product, comprising the steps of: providing information to a consumer, the consumer residing in a dwelling, wherein the information describes half-products and methods for contacting a distributor of half-products; and receiving an order from the consumer for a bulk quantity or a consumer-sized quantity of one or more types of half-products; and shipping the order to the dwelling of the consumer or to a nearby distributor of half-products.

47. The method according to claim 46 wherein the information includes descriptions of toppings, puffing devices and recipe books, further wherein the method for contacting the distributor is by wired or wireless communication including facsimile, telephone, e-mail, Internet, electronic data interchange, cable, private delivery service or regular mail.

48. A method of preparing, distributing and consuming a puffed food product, comprising the steps of: manufacturing bulk quantities of half-products at a mass production facility; shipping the half-products to a puffing facility capable of producing puffed food products in accordance with local taste preferences; and transporting the puffed food products to one or more food service facilities, the food service facilities close to established shipping channels.

49. The method according to claim 45 or 48 wherein the food service facility is a grocery store having display shelves for displaying half-products and toppings, further wherein the half-products and toppings are displayed in close proximity to each other.

50. The method according to claim 49 wherein the grocery store is less than about 20 km to 150 km or more from the mass-production facility and the consumer lives less than about two (2) km to 20 km or more from the grocery store.

51. A pellet puffing apparatus, comprising: a puffing chamber of a unique size for puffing one or more types of half- products at one time; and an adapter for adapting the apparatus for commercial or consumer use, wherein the puffing apparatus operates on a continuous or batch basis.

52. The apparatus according to claim 51 comprising a device selected from the group consisting of a hot air popper, a convection air oven, a frying device, a vacuum device, a microwave oven or a device custom-designed for puffing pellets, wherein the device produces a freshly puffed food product after a period of time.

53. The apparatus according to claim 52 wherein the hot air popper is a cyclonic hot air popper having a cover and the convection oven is a normal convection oven or an air impingement convection oven.

54. The apparatus of claim 52 wherein the puffing chamber in the frying device is a frying chamber for holding oil.

55. The apparatus according to claim 52 further comprising a heater connected to the puffing chamber for heating the puffing chamber to temperatures between about 120 °C to 315 °C wherein the puffing chamber holds at least one half-product to about 50 kg of the half-product.

56. A puffing apparatus comprising a puffing chamber, the puffing chamber comprising a dryer for drying and puffing a half-product to produce puffed cereal, a toaster for toasting the puffed cereal to produce toasted puffed cereal, and an enrober for coating the toasted puffed cereal to produce coated toasted puffed cereal.

57. A pellet-puffing apparatus, comprising: one or more bins of one or more types of half-products; a puffing chamber for expanding a predetermined quantity of the half- product to produce a freshly puffed food product; a fee collector for collecting a fee from a consumer using the machine; and a dispenser for dispensing the freshly puffed food product.

58. The apparatus according to claim 57 wherein the time period from the fee collecting to the freshly puffed food product dispensing is less than about 30 seconds to about four (4) minutes or more.

59. An apparatus for puffing one or more half-products to produce a freshly puffed food product comprising a puffmg chamber and a heater, the puffmg chamber comprising a vacuum chamber maintained at a pressure less than about one (1) Ton, and the heater heats the half-product to its glass transition temperature.

60. The apparatus according to claim 52 or 56 or 57 or 59 wherein toppings and oil are admixed with the freshly puffed food product or coated toasted puffed cereal.

61. The apparatus according to claim 60 further comprising a grinder for grinding the coated toasted puffed cereal to produce ground food product, further wherein the ground food product can be used in beverages, frozen food products or toppings; and

62. The apparatus according to claim 52 or 56 or 57 or 59 further comprising: a half-product moving device located inside the puffmg chamber for periodically moving the half-product during puffmg for a total of about 15 seconds to about three (3) minutes; a half-product dispenser connected to the puffing chamber for dispensing a predetermined amount of the half-product into the puffmg chamber; a timer, thermometer and controller connected to the puffing chamber; and a toppings dispenser connected to the puffmg chamber for dispensing a predetermined amount of toppings.

63. The apparatus according to claim 62 wherein a time period beginning with dispensing the half-product and ending with delivering the freshly puffed food product to a consumer is between about 15 seconds up to about two (2) days or more.

64. The apparatus according to claim 63 further comprising a computer control system having instructions for storing, displaying and processing recipe information necessary to operate the apparatus.